Device for creating digital signals representative of a natural leaf profile

ABSTRACT

There is provided a digital device for creating a series of digital signals indicative of the profile in certain surface variations of a natural tobacco leaf. The light intensity characteristic of an emitted light from various locations on the natural tobacco leaf are scanned in succession across the leaf at parallel positions. The light intensity at the various locations creates a digital signal indicative of whether or not the light intensity is high, low or intermediate. The color profile of the leaf could be created by these signals; however, in accordance with the invention, a digital signal is created when the light intensity signal shifts from one value to another. At that time, a transition signal is created which can be combined to form a transition profile of the leaf which is indicative of the actual profile and color variations of the leaf itself. This information can be used for locating a wrapper cutter at the desired position on the leaf for subsequent cutting of the wrapper from the leaf.

The present invention relates to the art of creating a digital signalpattern representative of a variable profile and more particularly to adevice for creating a digital signal profile representative of theprofile and color variations in a natural tobacco leaf. The inventionwill be described with particular reference to a system and method ofcutting cigar wrappers from a natural tobacco leaf wherein the inventionis used to create a profile of a natural tobacco leaf and its colorvariations; however, the device has broader applications and may be usedin other systems wherein the profile of a natural product such as atobacco leaf is required for subsequent processing or for a sheetproduct having variable or randomly positioned color variations whichmust be located for subsequent processing. The fact that the device isdescribed in its preferred intended environment of a tobacco leafwrapper cutting system or method, is not intended to limit the generalapplication of the device for other purposes.

CROSS REFERENCE

This application claims subject matter from a companion, copendingapplication Ser. No. 884,849, filed March 9, 1978 and owned by a commonassignee.

BACKGROUND OF THE INVENTION

In the production of cigars, a core is usually provided. In practice,the core is formed either of small tobacco pieces or whole tobaccoleaves bunched in a longitudinal direction. These cores are usuallywrapped with a binder and then spirally wrapped by an elongated sheet,known as a "wrapper". The cigar wrapper is formed by cutting a givenprofile from a tobacco sheet product. In some instances, a wrapper iscut from a synthetic tobacco sheet. However, it is desirable to providea natural tobacco leaf as the outer cigar wrapper to present anappealing appearance which facilitates marketing of the finished cigar.It is essential for a quality cigar that a natural tobacco leaf be usedfor the outer wrapper and that the finished cigar have no noticeabledefect, such as a hole, a color variation, an edge portion of the leaf,or a stem. Indeed, certain unduly noticeable heavy veins should not beincorporated into a wrapper for a quality cigar. All of these conceptsin wrapper selection are essential in the marketing of a cigar in thevery competitive cigar industry. The wrapper is important in determiningthe overall visual concept that a purchaser forms regarding the qualityof the cigar. Consequently, the wrapper must have an appearance thatimparts an impression of quality to the resulting cigar.

As is well known in the cigar industry, the wrapper, which is helicallydisposed in overlapping fashion around the cigar, must also have asmooth outer appearance which is somewhat difficult to obtain since theshape of the cigar often varies along its length. For that reason, thewrapper must be cut in a complex shape and must be accurately spiraledaround the cigar core and/or binder to produce the desired smooth outerappearance. This requirement, combined with the demand for a cigarwrapper with no surface defects, has made one of the more criticalaspects of cigar making the system by which the cigar wrapper is cutfrom a natural tobacco leaf. This system is made quite complex by thefact that each natural tobacco leaf has different surface variationswhich must be excluded from a wrapper.

Due to the extreme criticality in producing quality cigar wrappers foruse in cigar manufacturing, the wrappers are generally cut by a manualorienting procedure that has not changed substantially over the years.The process requires a skilled operator who manually orients a half of aleaf formed by removing the center stem. This leaf portion or half isexamined for holes, coarse veins, or other visible imperfections on onesurface. After this inspection, the leaf portion is usually spread ontoa cutting surface including a cutting die surrounded by perforatedsurfaces through which vacuum can be applied to the spread leaf. Theleaf is manually positioned over the cutting die to insure that theoutline of the die, which has the shape of the cigar wrapper, does notinclude an edge portion or any other visible surface imperfection in thenatural tobacco leaf. After this placement has been made, the vacuum isapplied to hold the leaf in place on the cutting surface. A roller isforced over the leaf and cuts out a leaf portion determined by theprofile of the cutter over which the leaf was positioned. After a firstcut has been made, the vacuum is released, the wrapper is removed andthe cut tobacco portion is again oriented by the operator for a secondcut from the leaf half, if a second cut is possible without includingany surface imperfection. The wrapper has an elongated shape and theleaf veins must have a predetermined diagonal orientation in thewrapper. Consequently, the general disposition of the wrapper cut mustbe generally parallel to the original stem of the natural tobacco leafwithin a few degrees, such as 10°-15°. In this manner, the veins, whichare found on the leaf, will have the proper pattern when the wrapper isspirally wound around the core and/or binder to form a finished cigar.This process of manually orienting and then cutting is continued untilno other wrapper can be cut from a leaf half. At this time, the leaf isremoved from the cutting station for use in other tobacco products ordiscarded. Other procedures are used in the tobacco industry forproducing the cigar wrappers. This particular description isrepresentative in that each of the procedures involves manualmanipulation of a leaf or a leaf half into a particular position whereina cut is made in the natural tobacco leaf so as to avoid surfaceimperfections. In all instances, an operator, who must be skilled andhighly trained, is required for the production of a quality wrapperproduced from a natural tobacco leaf. In practice, the cost of producingthe quality wrapper is a relatively high proportion of the cigarmanufacturing costs in that the remainder of the cigar making process isgenerally mechanized and can be accomplished at relatively highprocessing speeds.

In view of this, there is a substantial demand for an arrangementwherein the cigar wrapper can be cut from a tobacco leaf in a high speedoperation involving no manual manipulation without sacrificing the highquality required for the production of such wrappers. The advantage tothe cigar manufacturing process of avoiding, or reducing, the manualmanipulation required in producing the cigar wrappers is well known inthe industry.

Before the leaves are stacked for use by an operator, the heavy stem ormid-rib of each tobacco leaf is removed. Each resulting half of the leafis then "booked" in a separate pile for use in the cutting operation.Since the veins in the leaf extend diagonally in different generaldirections with respect to the stem, one half of the leaf is used forone cigar making machine and the other half of the leaf is used foranother cigar making machine. This prevents mixing of wrappers from bothleaf halves so that the diagonal veins within the cigar wrapper areuniform for each run of cigars. If whole leaves were provided to theoperator for manual orientation and cutting, the cut wrappers could havedifferent vein patterns unless the operator exercised extreme care andattention. Such mixing of vein patterns would not be acceptable in theproduction of cigars. The wrappers must be consistent in the orientationof the vein angles. Consequently, not only have prior arrangements forcutting cigar wrappers required manual manipulation, but they haverequired stemming of the tobacco leaf and grouping the leaves in"booked" and matched halves for use in a particular tobacco wrappingmachine. Stemming, booking and other controls have increased the cost ofwrappers without increasing their quality. All of these disadvantagesare known in the cigar industry and attempts have been made to correctone or more of the various disadvantages experienced in the previouslyused arrangements for producing cigar wrappers from natural tobaccoleaves.

The most common approach to solving the problems in cutting wrappers hasbeen to mechanize or increase the speed of the cutting operation and thewrapper transfer operation. Such a concept is shown in U.S. Pat. No.3,591,044. This patent is incorporated herein by reference forbackground information only. Such an arrangement increases production byan operator, but it does not solve the basic problems involved in theefficient production of a wrapper from a natural tobacco leaf. Manualmanipulation or orientation, stemming and booking of leaf halves arestill required. This was the background situation presented when thepresent novel system was developed to cut cigar wrappers from naturaltobacco leaves.

THE INVENTION

The present invention relates to a device for creating a digital signalpattern representative of a natural tobacco leaf or similar sheetproduct having variations in the surface which must be located forsubsequent processing.

In accordance with the present invention, there is provided a device forcreating a series of digital signals indicative of the profile andcertain surface variations of a natural leaf. This device comprisesmeans for supporting the leaf in a spread condition on a member andmeans for sensing light emitted from a succession of locations on themember by a scanning operation which scans the emitted light at selectedlocations in succession in a given path and then in successive paths,parallel to the given path, until the light emitted from all locationson the area of the member covered by the leaf are scanned. A firstdigital pattern signal is created when a location has a light intensitygreater than the preselected level. A second digital pattern signal iscreated when the light intensity at a location is below a selected levelless than the preselected level. There is also provided means forcreating a third digital pattern signal when there is no first or seconddigital pattern signal for a scanned location. These pattern signals areused for creating a transition signal for any location where the priordigital pattern signal is different from the scanned digital patternsignal. Also, the pattern signal to which the transition signal is beingmade is determined and registered. Thereafter, the transition andregistered pattern signal is recorded in a matrix corresponding to thescanned pattern.

In accordance with another aspect of the present invention there isprovided a method of creating, in a digital memory, a positionaloriented digital representation of the outline and distinct lightintensity variations of a natural tobacco leaf having two generallyparallel large surface areas. This method comprises supporting the leafin a spread condition on a member, illuminating the leaf to create anemitted light ray pattern corresponding to the shape and surfacecoloration of the leaf, measuring the emitted light intensity at knownlocations on the support member wherein the locations combine to coverthe leaf and part of the member; and then creating a first digitalsignal when the light intensity of the location is above a selectedfirst level, a second digital signal when the light intensity for alocation is below a selected second level and a third signal in theabsence of the first and second digital signals for a given location.This method involves creation of a digital transition signal for each ofthe locations wherein the digital representation shifts from one of thedigital signals to another of the digital signals and storing thedigital transition signals and information identifying the locationthereof in the memory.

By using the device and method as defined above, separate locationsacross a spread leaf are read by a scanning device which detects whetheror not the emitted light which may be passed through the leaf in someinstances is above a first level or below a second level. If above thefirst level, the sensed light intensity creates a given digital signalindicative of a maximum light intensity condition termed "white". Thesecond digital signal is a minimum signal and is indicative of a minimumcolor condition termed "black". If neither of these signals is created,a third signal is generated which is an intermediate light intensitysignal termed "gray". As so far described, a large number of locationsacross the supporting surface of a leaf are read and the light intensitythereof is determined. If this raw data were stored in a memory unit, asubstantial amount of memory space would be required. In accordance withthe present invention, a digital circuit is provided and a method isused wherein only transitions from one of the digital signals to theother is transmitted to a storage unit. In this manner, the profile of anatural leaf and its surface conditions can be created as a series oftransitions between the three spearate color created digital signals. Ofcourse, gradations of the gray signals could be registered as aplurality of intermediate signals by further circuitry. By using onlythe transition signals, the memory required for storing the totalpattern of the natural leaf for subsequent processing is drasticallyreduced which allows the use of a lower level memory unit.

The primary object of the present invention is the provision of a deviceand method for creating a digitized profile of a natural sheet product,such as a natural tobacco leaf, which device and method detects lightintensity at successive locations to create three or more distinct lightintensity digital signals and then determines which location experiencesa transition in the light intensity signal and the type of transition.In this manner, the profile can be created by the transition informationas opposed to the raw light intensity data.

Still a further object of the invention is the provision of a device andmethod as defined above, which device and method requires a lesseramount of storage capacity for storing the digitized profiles of anatural sheet product.

These and other objects and advantages will become apparent from thefollowing description which is incorporated with a description of asystem and method of cutting cigar wrappers from a natural tobacco leafas the preferred use of the claimed invention.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a top plan view illustrating a natural tobacco leaf from whichthe wrappers are to be cut;

FIG. 2 is a schematic view illustrating the shape of the cigar wrapperto be cut in the preferred embodiment together with the encompassingprofile or facsimile shape shown in dashed lines to be used in locatingthe cut position on the leaf shown in FIG. 1;

FIG. 3 is a top plan view of the leaf shown in FIG. 1 with the cutterprofiles located in cut positions;

FIG. 4 is a block diagram showing schematically certain general featuresof the preferred system;

FIG. 5 is a block diagram outlining control concepts employed in thepreferred system of the present invention;

FIG. 6 is a flow chart block diagram illustrating interfacing conceptsbetween the computer and the programmable controller as shown in FIG. 5;

FIG. 7 is a schematic, side elevational view showing the scanningmechanism and the transfer arrangement employed in the illustratedembodiment of the present invention;

FIG. 7A is an enlarged cross-sectional view showing certain features ofthe structure illustrated in FIG. 7;

FIG. 7B is a schematic representation of the light intensity transducerunits used in the illustrated embodiment of FIG. 7;

FIG. 8 is a logic diagram illustrating in block diagram and logicdiagram form the control system for the scanning operation to beemployed in the structure as schematically illustrated in FIGS. 7, 7Aand 7B;

FIG. 9 is a schematic differential circuit which would create lightintensity outputs as graphically illustrated in FIG. 8;

FIG. 10 is a chart showing an operating characteristic of the lightintensity scanning arrangement employed in an embodiment of the presentinvention without the preferred modification as contemplated by thesystem as shown in FIG. 11;

FIG. 11 is a block diagram of the circuit for modifying the video outputof the scanning unit to produce an output modified from that of FIGS. 8and 9;

FIG. 12 is a graph illustrating the operating characteristics of thecircuit shown in FIG. 11;

FIG. 13 is a block diagram of the memory loading concept which could beemployed in the system when raw data of all locations is used forcreating a leaf facsimile;

FIG. 14 is a logic diagram illustrating a system for creatingtransitions in the scanning operation for use as intermediate data inthe preferred embodiment of the present system;

FIG. 14A is a simplified logic diagram illustrating a transition datacombining digital circuit employed in conjunction with FIG. 14 and usedin the preferred system;

FIG. 15 is a block diagram illustrating a data transfer system whichcould employ the data developed by the structure illustrated in FIG. 14and digital circuitry for processing and inputting such data;

FIGS. 16 and 17 are data transfer circuits similar to that shown in FIG.15 but employing the data developed by the schematic digital circuit ofFIG. 14A;

FIG. 18 is a block diagram illustrating the direct access memory loadingconcept used in the preferred system wherein transition data is loadedinto separate memory units or areas;

FIGS. 19 and 20 are tabulations of direct memory entered data employedin the preferred system of the present invention;

FIG. 21 is a schematic view illustrating a natural tobacco leaf andcertain scanning concepts employed in the preferred scanning concept ofthe system;

FIG. 22 is a vectorized outline of the natural leaf shown in FIG. 21 asemployed in the preferred processing concept of the system;

FIGS. 23, 24 and 25 illustrate further concepts used in processing dataemployed in the preferred system;

FIG. 26 is an outline of the computer program steps employed in thepreferred system of the present invention;

FIG. 27 is a top plan view of an embodiment of the present inventionillustrating the various structural features of a system for locatingthe cuts on a natural tobacco leaf, transferring the tobacco leaf to acutting platen, cutting the cuts from the natural tobacco leaf andconveying the cuts or wrappers to a successive position for processing;

FIG. 28 is a schematic view taken generally along lines 28--28 of FIG.27;

FIG. 29 is an enlarged cross-sectional view taken generally along line29--29 of FIG. 27;

FIG. 30 is an enlarged plan view of the cutting head taken generallyalong line 30--30 of FIG. 29;

FIG. 31 is a side cross-sectional view taken generally along line 31--31of FIG. 29;

FIG. 32 is a side elevational view showing the cutting platen in thecutting position;

FIG. 33 is an enlarged cross-sectional view taken generally along line33--33 of FIG. 27;

FIG. 34 is a graphic view of the cutting table employed in the preferredmechanism of the present invention;

FIG. 35 is a cross-sectional view of the cutting table as illustrated inFIG. 34;

FIG. 36 is a top plan view showing in more detail the cutting platen andcutting table employed in the preferred embodiment of the presentinvention;

FIGS. 36A, 36B are plan views illustrating the operating characteristicsof the structure shown in FIG. 36;

FIG. 37 is a cross-sectional view of the digital motors in the structureillustrated in FIG. 36;

FIG. 28 is a cross-sectional view taken generally along line 38--38 ofFIG. 37;

FIG. 39 is a schematic logic diagram illustrating operatingcharacteristics of the structure shown in FIG. 37;

FIG. 40 is a schematic view of a modification of the illustratedpreferred system showing certain features of the present invention;

FIG. 40A is a schematic view showing a modified portion of the structureas illustrated in FIG. 40;

FIG. 41 is a further embodiment of the present invention wherein thescanning, cutting, loading and unloading of a natural leaf onto thecutting platen is done at angularly positioned locations and the cuttingoccurs on the same support structure as used during the scanningoperation;

FIG. 42 is a schematic view illustrating the grid coordination conceptemployed in the preferred embodiment of the present invention; and,

FIG. 43 is a simplified schematic view illustrating a modification ofthe invention as could be used in the schematic structure illustrated inFIG. 41.

DESCRIPTION OF INVENTIVE CONCEPTS, PREFERRED EMBODIMENTS ANDMODIFICATIONS THEREOF

The present invention relates to a method, system and apparatus forcutting one or more profiles, such as cigar wrappers, from a naturalleaf, such as a tobacco leaf. A natural leaf has veins, colorvariations, a stem in most instances, holes and various defects whichare not to be included in the profile cut from the leaf. As a generaldescription, the invention relates to the method, system or apparatusfor accomplishing this primary objective by using a constructed profileor image of the leaf which depicts the defects, without using anymarking arrangement. The system uses this constructed profile or imagefor selecting the cut position or positions in a manner generallyoptimizing the number of wrappers and the quality of wrapper taken fromthe available surface area of the leaf. The basic and total concept ofthis method, system and apparatus will be explained in detail. Theappended claims set forth the inventive concepts relating to this totaldescription which will be separated into areas for illustrating thevarious aspects of the method, system and apparatus contemplated.

GENERAL CONCEPTS (FIGS. 1-6)

Referring now to FIGS. 1-3, a natural tobacco leaf L has known physicalcharacteristics in that it is flaccid, pliable and has internal colorvariations, energy ray detectable variations and defects like holes, anddark or black areas. In addition, the natural tobacco leaf has a topsurface which is to be used as the exposed portion of the wrapper to becut from the leaf. Natural leaf L is illustrated as including a centerstem 10 which extends in a somewhat undulating path longitudinallythrough the leaf, a plurality of holes 12 of varying size, diagonallyextending right and left veins 14, 16, respectively, dark areas 18 andan outline or edge 20. The dark areas 18 may be on either surface of theleaf and are visible from the top surface to a degree determined bytheir location. Indeed, the dark areas may be internal of the leaf andpresent only a slight color variation when view from the top surface ofthe leaf. Even in that situation, the dark areas could be consideredunacceptable for a wrapper of a cigar. Also, abrupt surface colorvariations can occur as pronounced light areas in the leaf which may bedetectable from one or both surfaces of the leaf and which may beundesirable for a cigar wrapper. From the leaf L cigar wrappers W, asshown in FIG. 2, are to be cut by a cookie cutter type die or clickerdie commonly used for cutting of flat sheets in other industries.Wrapper W has a precise shape which allows spiral winding of the wrapperaround the binder and/or core of the cigar without producing wrinklesand surface defects. The wrapper generally includes a head H and aportion T called a "tuck". Tuck T is ultimately located in the end ofthe cigar to be lighted, whereas head H is twisted and wrapped into theportion of the cigar to be held in the smoker's mouth. These shapes arecritical and it should be free of dark areas, any holes and heavy veins.The shape of wrapper W, which varies for different length and shapedcigars, can be circumscribed by a four-sided profile 30. The profile isdifferent for left and right hand wrappers and are configurations 30a,30b, as shown in FIG. 3. The cutters are labeled CUTTERS 1-4. In thisillustrated embodiment the cutters outlined by the shapes 30a, 30brepresent cut positions of the same wrapper shapes. In some instances,two or more wrapper shapes could be cut from a single leaf. For thepurpose of describing the present system, the cutter to be used in thewrapper has the shape of wrapper W; however, the profile 30 or profiles30a, 30b are used to locate the cut positions for the wrappers on thesurface of leaf L in a manner to avoid any unwanted defects in theresulting wrapper within the confines of general profiles 30a, 30b. Inproducing wrappers W from leaf L the wrapper profile must be located onthe leaf to avoid defects such as holes, the stem, dark areas, colorvariations of a given magnitude and other such contingencies to producea wrapper having the quality set forth in the introductory portion ofthis application. In most arrangements for cutting the wrapper W from anatural tobacco leaf, the stem is removed and the leaf halves are bookedor stacked according to the right hand vein arrangement or the left handvein arrangement. The present system does not contemplate the stemmingof the leaf; however, it could be stemmed and a half of a leaf could beprocessed in the present system. Throughout the rest of the discussionof the present system, wrapper profile 30 is used to locate the cutpositions on leaf L of the cutter for a wrapper W since the placement ofthis profile at various non-conflicting locations will provide propercut positions for the circumscribed actual wrapper configuration. Inpractice of the present system, the actual profile 30 or profiles 30a,30b are slightly greater in size than the contour of the wrapper cutterso that the cut made by the cutter itself will not be at the edge of theleaf or closely adjacent a prohibitive defect to be excluded. In otherwords, the profile used in selecting the cut positions in accordancewith the system herein described is slightly larger than the actualcutter profile used in making the wrapper cut in leaf L so that the cutis offset at least a small amount from the outline of profile 30.

In accordance with the system contemplated by the present invention, aprofile or image of the leaf including the outline, stem, surfacevariations and defects is created and recorded and stored. Thereafter,the profile 30 is manipulated within stored profile or image to locatepositions in which the profile 30 avoids unwanted defects and remains inthe confines of the leaf. These selected cut positions are then used tocontrol a cutting machine that positions the leaf and wrapper cutter inthe desired relative position for a cutting operation to remove thewrapper from the area bound by profile 30 in its final selected positionor positions.

A general functional block diagram of the overall system isschematically illustrated in FIG. 4. A description of this block diagramwill provide general information regarding the basic concept of thesystem hereinafter described and can be used as an over view of thesystem of cutting wrappers W from desired positions on leaf L withoutrequiring the previously used manual manipulation and withoutsacrificing quality of the resulting wrappers. In accordance with thefunctional block diagram, a natural leaf is spread onto a vacuum supportsurface which preferably is capable of transmitting light rays so thatthe rays pass simultaneously through the surface and through the leaf.These rays are read by a light intensity sensitive device whichdetermines the light intensity at selected locations on the supportsurface. The total light intensity pattern provides a light intensityprofile or image of the natural tobacco leaf supported in a spreadcondition on the surface. The concept of spreading the natural leaf ontoa vacuum support surface for cutting is known and is represented byblock 40. The concept of passing light through the leaf supported on avacuum surface is novel and is represented in block 42. As indicated byblock 42, the leaf is indexed or moved incrementally in one direction(hereinafter called the Y direction) and the light intensities atselected areas of the leaf across another direction (hereinafter calledthe X direction) are recorded at identifiable locations identifiable byboth X and Y positions on an imaginary grid on the vacuum surface. Theintensity of the light passing through the leaf at these variousidentifiable locations which cover the total leaf as it has been movedare indicative of the contour of the leaf and color variation or defectsincluding holes, dark areas, the stem, the veins and other surface colorvariations. By passing light through the leaf, variations on bothsurfaces are detected as are variations within the leaf which can causediscernible color variations that would be objectionable in a wrapperfor a cigar. Block 42 is indicative of this scanning operation forobtaining light intensity at selected locations encompassing the totalsurface area of natural tobacco leaf L. The scanning operation creates aseries of light intensity signals which are each analog voltages. Onevoltage signal corresponds to each scanned location and appears in line44. Digital data indicative of the location of the scanned locationssimultaneously appears in line 46. The analog light intensity signal inline 44 is converted to digital data indicating whether or not thescanned location has a light intensity value indicative of white, blackor an intermediate color, termed "gray". Thus, each of the scannedlocations on the leaf, which may be as small as desired and is known asa Pixel, will produce a light intensity, digital signal in line 50. ThePixel data will be white, black or gray. If desired, variations of graycould be obtained; however, such resolution is not required in thepresent system. The address data in line 46 identifies the location ofthe Pixel being detected and transmitted in line 50. As can be seen, ifthe leaf is segregated into a large number of identifiable locations, orPixels, which have known addresses (in the X and Y directions) and knownlight intensity conditions, such as white, black or gray, a profile ofthe leaf itself can be constructed remote from the leaf. Forillustrative purposes, a sequencer 60 is indicated as transmitting thedigital information regarding the color of the Pixel and the location ofthe Pixel to any type of storage unit 70 by lines 72, 74. The particularstorage arrangement will then contain a matrix indicative of the profileof the leaf including an outline and defects. This data matrix storageunit 70 is indicated to be a sequenced unit incremented by line 469 foreach Pixel in the X direction. In practice, storage unit 70 is a directaccessed memory usable by a digital computer in accordance with knowncomputer practice. The indexing by each X Pixel will cover all Y indexesin sequence. Proceeding further into the schematic representation of thegeneral system as shown in FIG. 4, cut locations or positions aredetermined as represented by block 80 using the stored digital data instorage unit 70. This can be done in a variety of computer arrangementswhich will be described in more detail later. Basically a digitalrepresentation of the cutter profile 30 is compared to the storeddigital profile of leaf L in storage unit 70 and these two profiles areshifted until the digitized profile 30 does not include a defect, suchas a hole, edge of the leaf, or undue color variations. After one cutposition is located, a next profile 30 is also shifted with respect tothe digitized leaf profile or image in storage unit 70 to locate still afurther cut position which avoids the defects set forth above. Thisprocess is continued until the digitized representation of profile 30 isset to the extent possible to obtain the desired number of cuts in leafL. The various cut locations so located by shifting the digitizedprofiles 30 within the digitized leaf profile of storage unit 70 are inthe form of X, Y and φ corresponding to the X, Y location of a selectedpoint on a line of profile 30 and the angle this line makes with thescanned Y direction. The X, Y and φ coordinates are then converted tousable cut coordinates represented as X1, X2 and Y by a coordinatearithmetic conversion. This conversion is determined by the usable datanecessary to obtain the same X, Y and φ location on the cutting machinewhen a linear converting mechanism is used for purposes to be explainedlater. Arithmetic conversion to cut coordinates usable in the specificmachinery contemplated for actually making the cut in the leaf isrepresented by function block 82. After the scanning operationschematically illustrated as block 42 has been completed, leaf L istransferred to a cutting platen or table. This process is represented byfunctional block 90. After the leaf has been transferred to the cutplaten, the arithmetically generated coordinates from generator 82 aredirected through an interface indicated generally as line 92 to adigital-to-analog movement mechanism 100. This mechanism shifts the cuttable carrying the leaf to a known cut position determined bycoordinates from interface 92. As will be explained later, the movementby mechanism 100 is translated along three axes corresponding to X1, X2and Y coordinates. The moving to a cut position is represented by block102. The transfer of leaf L to the cut table is in an oriented positionand the cut table is a vacuum surface which holds leaf L in thisoriented position. The coordinates from generator 82 operate on thetable as they would on the scanning surface. After the leaf and tablehave been shifted to the first cut position, the wrapper cutter isshifted downwardly to cut a cigar wrapper from the leaf in this firstcut position. This action is represented by functional block 104. Thecutter is then raised to remove the wrapper from the leaf, which leaf isstill held on the table by vacuum. The wrapper is held by a vacuum meansas the cutter moves upwardly. This removes the wrapper from the cuttingtable as represented by functional block 106. Thereafter, the wrapper isremoved from the cutter by a vacuum transfer arrangement in accordancewith known wrapper handling procedures. This functional step isillustrated as block 108. Interface 92 then causes a recycling of thecutter table to the second cut position and a second wrapper is cut,removed and stored for subsequent use. This procedure is continued untilall the cuts located within leaf L have been made. Thereafter, the nextleaf is processed.

In accordance with the preferred embodiment, while the cutting operationis taking place on one leaf, a second leaf is being spread on the vacuumsupport surface and scanned and the cut positions are being located andthe coordinates X1, X2 and Y are being created. Thus, a tandemarrangement is contemplated wherein the scanning is taking place on oneleaf while the cutting operation is taking place on a previous leaf. Tofacilitate this dual operation, a general control system, as shownschematically in FIG. 5, is employed in the preferred embodiment. Thesystem includes, as basic machine elements, a scanning mechanism 200, aleaf transfer mechanism 202, a locate and cut mechanism 204, a wrapperremoving mechanism 206 and a mechanism 208 for removing the spent leafafter all the cuts have been made from the leaf. All of thesemechanisms, which will be explained in more detail later, are controlledin accordance with a standard practice by a commercially availableprogrammable controller 210, such as one using an Intel 8080microprocessor. The sequence of mechanical operations are conducted inaccordance with the program of the programmable controller in accordancewith standard practice in machine control operation. The scanningmechanism 200 provides information to a direct access memory 220 whichhas a two-way communication with a standard digital computer 240 thatlocates the cut positions, converts them to X1, X2 and Y coordinates adprovides the coordinates to the controller 210. A two-way communicationwith the programmable controller is provided to load the cut positionsinto the programmable controller when the programmable controller isready to accept the cut coordinates for processing a scanned leaf L. Thecontrol and function of information provided in FIGS. 4 and 5 isillustrative in nature to show the general process being performed inaccordance with the novel system and a general control arrangement whichallows the various mechanisms to be operated to cut wrappers from leafL. This use of a controller 210 reduces computer time and software andprovides a standard type of machine control for the various mechanismsused to perform the sequence of events set forth generally in FIG. 4.

Referring now to FIG. 6, this figure illustrates, somewhat generally,the interface 92 between the programmable controller 210 and the digitalcomputer 240 as represented in FIG. 5. Also, the information fromcomputer 240 is illustrated in FIG. 13. As a first step, theprogrammable controller 210 acknowledges that it desires access to thedigital computer 240 for data regarding the cut coordinates for leafdesignated as "leaf A". Thereafter, the programmable controller obtainsand stores the number of the cut (1, 2 ...n), the particular cutter(cutter 1, 2, 3, etc), the coordinates X1, X2 and Y for the first cut.It is possible to use different cutters to obtain different wrappersizes. For that reason, the particular cutter to be used is inputted tothe programmable controller. In addition, as noted in FIG. 3, there areleft and right hand wrapper cutters to accommodate the different veinconfigurations. Thus, if a cut is to be made from one side of the leaf,one cutter is selected, whereas another cutter is selected for a wrapperfrom the other side of the leaf. Because of this, the programmablecontroller receives information regarding which cutter is to be used,which cuts are to be made and where the cut is to be made on the leaf.Thereafter, the programmable controller waits for access again from thecomputer, acknowledges access and receives the information regarding thesecond cut. This continues until the programmable controller receivesinformation regarding all n cuts to be made in leaf A. At that time, theprogrammable controller acknowledges that all information has beenreceived with respect to leaf A and proceeds to initiate the controllerfor processing leaf A. After leaf A has been processed, the programmablecontroller then receives information regarding the cut positions andcutters from the digital computer for making the cuts in the next leaf.The cutting operation is proceeding as the scanning operation for thenext leaf is proceeding. FIGS. 4, 5 and 6 are to be taken together toillustrate one arrangement for accomplishing the system contemplated bythe present invention. The details of the system will be hereinafter setforth. However, it should be appreciated that there are several machinecontrol arrangements and computer arrangements which can be employed inpracticing the method and system contemplated by the description herein.

SCANNING AND CREATING DIGITAL FACSIMILE DATA (FIGS. 7, 7A, 7B and 8-12)

As explained with respect to the general description above, a system inaccordance with the present invention involves an arrangement forobtaining digital information regarding the light transmittedcharacteristics at various identifiable locations or Pixels (X, Ylocations) on a natural tobacco leaf L for processing of thisinformation to select available cut positions for one or more cuts to bemade in the tobacco leaf in the process of forming wrappers for cigars.As indicated in the block diagram of FIG. 4, used for illustratingcertain basic concepts of the system under consideration, block 42contemplates a scanning mechanism schematically represented as mechanism200 in the control concept block diagram shown in FIG. 5. A variety ofmechanisms 200 could be employed for the scanning operation to producethe desired digital information. One of the basic concepts of thepresent system is the generation of a signal, preferably digital,indicative of the surface or color condition of selected, knownlocations or Pixels on the tobacco leaf, which Pixels can be combinedand processed in a manner generally described above to give arepresentative facsimile, image or profile of the leaf including bothcolor variation and defects such as holes and dark areas and stems. Thisfacsimile, profile or image is then used to graphically orarithmetically locate the particular cut positions for subsequentcutting of wrappers from the natural leaf. To produce digitalinformation or data regarding the surface condition or color variationat locations on leaf L, mechanism 200 is used. This mechanism isschematically illustrated in FIGS. 7, 7A, 7B, 8 and 9 which show thepreferred scanning operation. In accordance with this illustratedembodiment, there is provided a continuously driven belt 300 movablearound spaced support rolls 302, 304 and having an upper surface 300aand a lower or inner surface 300b. For the scanning operation, the beltis transparent or translucent so that it can transmit light rays throughthe belt for a purpose to be described later. In practice, this belt istranslucent and formed from a material known as "Revo" which is a clearnylon belting supplied by L. H. Shingle Company and has a generalthickness of 0.04 inches. This standard nylon belting is provided withsmall perforations 300c extending through the belting to develop apositive pressure differential adjacent upper surface 300a when a vacuumis created adjacent lower surface 300b. The use of the vacuum at surface300a holds leaf L in a manually or machine spread condition on leafreceiving surface or support surface 300a in the "scan" position shownin FIG. 7. To drive the belt in a clockwise direction, as shown in FIG.7, there is provided an appropriate electric motor 306 connected to roll302 by a drive mechanism schematically represented as dashed line 308.An encoder 310 provides pulses in output line 312 when motor 306 hasdriven belt 300 axially a preselected distance. In practice, thispreselected distance is 0.05 inches. Consequently, an encoder pulse isprovided after each movement of 0.05 inches of belt 300 in the Ydirection indicated in FIGS. 7 and 7A. Below the belt in both the "scan"and "transfer" positions there is provided a vacuum box 320 of somewhatstandard design in the cigar making industry. This vacuum boxsubstantially traverses the "scan" and "transfer" positions of the upperrun of belt 300 between rolls 302 and 304. If the leaf is to be placedon belt 300 in the lower run, a vacuum box could be provided along thisrun and roll 302 could be a standard vacuum roll. Adjacent the scanposition there is provided a vacuum chamber 322 which is maintained at avacuum by an appropriate external vacuum source. In the transferposition, there is provided a chamber 324 which combines with chamber322 to form the total box 320. A pressure sensitive flapper valve 326separates chambers 322, 324 to allow selective transfer of the leaf by amechanism 202, which will be explained later. The leaf is to be removedfrom upper surface 300a of belt 300 in the transfer area after it hasbeen scanned. Transfer chamber 324 can be provided with a vacuum or withpressurized air. After a leaf has been scanned, it is moved to thetransfer position. At that position chamber 324 is pressurized. Thisallows the scanned leaf to be grasped by a vacuumized transfer head 328.This head has a lower vacuumized leaf receiving surface that holds theleaf L in an oriented position and transfers it to the cutting table ina manner to be described later. Thus, to transfer the leaf from belt 300to transfer head 328 pressure is applied to chamber 324 and vacuum iscreated adjacent the lower surface of transfer head 328. This transferhead and procedure is used often in the tobacco industry to transfertobacco products from a belt to another structure. When pressure isapplied to chamber 324, valve 326 closes to prevent loss of vacuum inscanning chamber 322. Of course, other arrangements could be used forholding leaf L by vacuum onto a scanning surface while the surface isbeing moved and then for removing the leaf from the scanning surface;however, the arrangement illlustrated in FIG. 7 is now contemplated foruse in the present system. Belt 300 is stopped momentarily for leaftransfer.

In accordance with the preferred embodiment of the present invention,scanning device 200 includes any appropriate mechanism for identifyingthe color content or the light intensity characteristics at variouspreselected locations or Pixels across the face of tobacco leaf L at Xand Y positions. In practice, the data creating mechanism is a scanninghead 340 which simultaneously records light intensity at spacedlocations across belt 300 in a direction, identified as the X directionin FIG. 7B. The X direction is generally orthogonal to the longitudinalor Y direction shown in FIGS. 7 and 7A. In essence, the scanning head340 receives light rays along a selected Y position which is indicativeof the light intensity viewed at given spaced positions across the leaf.The term "scanning" as used in conjunction with mechanism 200 and head340 means that these positions are read in series although they may besimultaneously detected. The scanning feature is provided by the circuitshown in FIG. 8. The light intensity at most locations in both the X andY directions of leaf L is measured and an output is createdrepresentative of this light intensity. Of course, certainapproximations are acceptable. Locations in the X direction are viewedby head 340 at spaced lines or positions in the Y direction. This cancreate certain small bands of undetected areas between adjacent Ypositions. This feature is minimized by shifting or moving the scannedposition only a small distance in the Y direction. This will providesufficient digital information or data for identifiable locations on thesurface of leaf L to create leaf profile for location of the profiles30. In practice, a LC 100 512 EC Reticon detecting or scanning head 340is employed. This type of unit is commercially available from ReticonCorporation of Sunnyvale, California. In this type of mechanism, a lens342 directs light rays from the surface of leaf L into an elongatedaperture 344. By using the lens, the view distance in the X direction atthe leaf area is focused onto 512 transversely spaced light intensitysensing units 350 each having a width approximately 2 mils.Consequently, the light profile in the X direction at a given Y positionis focused on and changes the charged characteristics of the lightintensity sensitive units 350 schematically illustrated in FIG. 7B. Inthis manner, light intensity at 512 different indexed or shiftedpositions in the Y direction of belt 300 are read simultaneously by theseparate units 350. This covers the total leaf width and much of surface300a. The Reticon unit uses a clocking pulse to step a shift registerwhich allows serial reading of the light intensity data of each 512units 350. This serial output is an analog video output as described inFIG. 8. The voltage of this video output is an analog representative ofthe light intensity exposed to each of the units 350 spaced in the Xdirection at a given Y position. The setting of units 350 in a given Yposition is not scanning; however, the output from the Reticon unit is ascanning function since it reads successive cells or units 350 andoutputs them in series as representative of the light intensitycondition viewed by the units across a given Y position. After all units350 have been read, scanning unit 350 is ready to receive the lightintensity at selected positions across the next adjacent Y position ofleaf L. To do this, belt 300 moves leaf L by motor 306. As will beexplained later, encoder 310 produces a signal in line 312 whichindicates that the units or cells 350 are now ready to read the lightpattern across the next successive longitudinally spaced position onsurface 300a which carries and supports leaf L. By progressing the belt300 in the Y direction, the output of the Reticon sensing head 350 readsthe identifiable transverse locations on surface 300a at the variousorthogonally spaced positions in the Y direction. The spacing betweenthe units 350 and leaf L is such that a distance of approximately 12.5inches is focused by lens 342 onto the 512 light sensitive units. Thisprovides a spacing in the X direction of approximately 0.025 inches ascompared to a spacing of approximately 0.05 inches in the Y direction asdetermined by the adjustable setting of encoder 312. As is known, the512 units or cells 350 are approximately 2 mils in width; therefore, thespacing of the units from the leaf and the lens produces a scan orviewing field in the X direction of slightly over 1:10. Otherarrangements could be used to change the viewed field across leaf L. Thesetting of unit 340 to provide a unit or cell 350 for each approximately0.025 inches has proven satisfactory and provides an identifiablelocation, or a Pixel, which is satisfactory in size. The Pixel has Ydirection dimensions of approximately 0.50 inches to give goodresolution for the ultimately constructed image or profile of the leafL. The output of the Reticon unit for each of the Pixels in the Xdirection is a video signal having a voltage level indicative of thesensed light intensity at the individual cells 350 being read by theReticon unit in accordance with standard practice for this type of unit.As so far described, scanning head 340 has produced an analog signal foreach of 512 positions across the surface 300a of belt 300 for a givenlocation of the belt in a Y direction. As the belt is moved by motor 306to a next position creating an encoder output in line 312 this processof providing output analog signals for 512 positions in the X directionis repeated. This action is continued until the total leaf has beenprocessed. In practice, there are 512 Y direction positions to combinewith the 512 X direction positions. Since the Y direction positions aresubstantially twice as great as the X direction positions, theidentifiable locations are more highly resolved in the X direction. Thesurface area on belt 300 being viewed by scanning head 340 measuresapproximately 12 inches across and about 25 inches in length. This issufficient to encompass natural tobacco leaves of the type used inproducing wrappers for cigars. This monitored field of view of coursecan be changed by the optics of the scanning operation and by changingthe number of Y direction positions used to complete a total scan of thesurface 300a carrying a leaf L. The belt can move continuously at a rateallowing Pixel reading.

To provide discernible light intensity for viewing by head 340, it ispossible to light the leaf on belt 300 by appropriately spaced lights352 schematically illustrated as arrows in FIG. 7A. These lights can beat angles to accentuate such surface conditions as veins or can beperpendicularly directed toward the leaf surface. In any instance, thisfront lighting arrangement does not allow head 340 to detect certainsurface defects, such as discoloration and defects within the leafitself and certain color variation on leaf surface. To provide a moreaccurate light intensity profile of the total leaf, the preferredembodiment of the system uses a back lighting arrangement wherein lightrays are passed simultaneously through belt 300 and leaf L. Thisprocedure produces high resolution light intensity profile at thedetecting cells 350. This back lighted profile is more nearly indicativeof the actual condition of the surface of the leaf, together withcertain conditions which may be within the leaf or on the oppositesurface of the leaf. Thus, one aspect of the system, as contemplated foruse in practice, is back lighting of the leaf to pass visible light raysor other detectable energy rays through both the belt 300 and leaf L. Inaccordance with this aspect of the novel system, there is provided atransversely extending apertured fluorescent light 360, with theelongated apertured window of the light extending generally parallel tothe aperture 344 controlling light flow to the units or cells 350. Thisaperture in unit 340 is approximately 17 mils in width. The light raysfrom the apertured fluorescent light 360 are directed through belt 300and leaf L, if the leaf is over the light, and into aperture 344. Anapertured fluorescent light for use in the system is a stock itemavailable from various sources and has an opening of approximately 30°and a reflective surface around the remainder of the interior surface ofthe light. This gives a directed light source aligned with the aperture344. Light 360 is fixed with respect to scanning head 340 by anappropriate mounting arrangement including a shield 362. This shieldfurther restricts the deflection of light from the area of the belt tobe illuminated. In FIG. 7A, an appropriate device, such as a photocell370, is used to detect the leading edge of leaf L as it is conveyed bybelt 300. This photocell creates a "start scan" signal in line 372 whichwill be used in the circuit illustrated in FIG. 8 for the purpose ofstarting the scanning operation.

Referring now to FIG. 8, a general scanning and output logic diagram forobtaining digital output facsimile data from the operation of scannerhead 340 is illustrated. In this illustrated logic circuit, the standardReticon reading device 400 is used to provide a series of analog databits on line 402 which correspond to the X Pixels which are outputted inseries by an external clocking pulse on line 404. These clocking pulsesare divided by an appropriate divider 406 to produce two input clocksφ1, φ2 for controlling the scanning operation of the sequential readingdevice 400. This sequencing device employs a shift register to read eachof the different units or cells 350 and to output an analog voltage online 402 for each cell. At the end of a sweep across the cells, there islogic 1 produced in the end of sweep (EOS) line 410. The clock at line404 may have a variety of frequencies; however, in practice it is in therange of 100 Kilohertz to 1 Megahertz according to the speed of theoutput signal required. Since a subsequent sweep is controlled bymovement of the belt 300, as shown in FIG. 7, a rapid sweep through the512 Pixels is employed. A conversion circuit 420, best shown in FIG. 9,produces a digital logic 1 in line 422 when the light intensity of aPixel being read produces an analog voltage in line 402 less than apreselected voltage level. This logic 1 is indicative of a "black"condition for a Pixel. In a like manner, if the analog voltage of aPixel is above a certain voltage level, which is indicative of a whitecondition, such as no leaf or holes in the leaf, a logic 1 appears inline 424. This is termed a "white" Pixel condition. A white or blackcondition indicated by the logic in lines 422, 424 control NOR gate 430which produces a "gray" digital signal in line 432 when there is neithera black or white signal. Thus, a Pixel being read produces either ablack, white, or gray digital output signal indicative of the lightintensity at the Pixel. The gray signal is generally indicative of thenatural color of the leaf being exposed to a cell 350. At the end ofeach sweep, a logic 1 in line 410 stops the video output at line 402.The sequencer 400 is initiated for a subsequent sweep by a logic 1 atthe start terminal S. To create a logic 1 in the start line 412, thereis provided an AND gate 440 having three inputs. Th first input 312 isthe output of encoder 310 shown in FIG. 7. A signal appears in line 312when the leaf is in the next Y position for a subsequent scan in the Xdirection. The second input to gate 440 is line 410 which is enabledwhen a prior sweep has been completed. The third input is line 450 whichis a logic 1 during the scanning operation. A logic 0 in line 450prevents scanning. A variety of circuits could be used for controllingthe logic of line 450; however, in the illustrated embodiment, aflip-flop 452 is set by a logic 1 in line 372 from the photocell 370shown in FIG. 7A. Thus, when a leaf is moved by belt 300 into thescanning position, a logic 1 appears in line 372. This sets flip-flop452 to enable gate 440. After the desired number of positions in the Ydirection have been processed, in practice 512, a logic 1 appears inline 454. This resets flip-flop 452 and shifts a logic 0 into the line450. This disables gate 440. Sweep start signals in line 412 can not becreated until the next leaf sets flip-flop 452. Consequently, at each Yposition a logic 1 is created at the output of gate 440 by line 312, ifa leaf is being scanned. This starts the next X sweep. A logic 1 in line412 not only starts a sweep, but also clocks flip-flop 460 to produce anenable signal in line 462. This enables X counting gate 464, controlledby gate 466, and enables increment gate 468. This latter gate isoptional for a purpose to be described later. A logic 1 in line 412 upcounts Y counter 480 by pulsing Y count line 482. All of these functionsare caused by a signal in line 312 as long as gate 440 is enabled bylines 410 and 450. As soon as a sweep has started, a logic 0 appears inthe line 410 which inhibits gate 440 until the X sweep has beenprocessed.

During an X sweep, output pulses are created in lines 422, 424 or 432.With each pulse, gate 466 clocks gate 464 to up count X counter 470.This produces the X address of the Pixel being read at the output of Xcounter 470. At the end of the X sweep, not only is gate 440 enabled,but X counter 470 is reset for the next sweep and flip-flop 460 is resetby line 474. This reset produces a logic 0 in the enable line 462 todisable counting gate 464 and incrementing gate 468. When Y counter 480reaches a count of 512 the Y counter is reset. Line 454 resets flip-flop452 to indicate that the scan is completed. Flip-flop 452 then preventsfurther scanning until the next leaf is available for processing.

In operation, for each sweep, the light intensity value of the Pixel andthe X address of the Pixel is available at the output of the circuitshown in FIG. 8. This information is available for each sweep until theY counter has indicated that the desired number of X sweeps has beencompleted. At that time, the sweep circuit is deactivated until the nextleaf is available for processing. The Y counter could be used to inputthe Y addresses for any given Pixel. In other words, the X address inlines 472 from X counter 470 could be combined with the output of Ycounter 480 to give not only the X address for the Pixel, but also the Yaddress. The Y address is not generally required in the illustratedembodiment of the invention because it is sequenced in series.

Referring now to FIG. 9, the converter 420 is schematically illustratedas including two differential amplifiers 490, 492 poled as shown andhaving voltage adjustable rheostats 494, 496 to control the respectivenegative terminals. An inverter 498 inverts the output of amplifier 490to produce a logic 1 in line 422 when a condition designated as "black"by rheostat 494 has been reached. Other arrangements could be used toconvert the analog video signal in line 402 to a digital logicindicative of the black or white conditions. Referring now to FIG. 10,this is a graph of a single X sweep across the leaf at a selected Yposition. For illustrative purposes, the leaf has a center stem 10 and ahole 12. It is noted that opposite edges of the leaf are indicated by awhite signal in line 424. The black stem is indicated by black signal inline 422. The hole 12 is represented by a white signal in line 424.Inbetween these extreme positions, logic 1 appears in line 432. Thisprovides the general profile for the remainder of the leaf which doesnot exhibit either a drastically white or a drastically black condition.A sweep as illustrated in FIG. 10 will be repeated 512 times for eachleaf L and the information provided during each sweep can be used tocreate a profile of the leaf indicating the defect areas which should beavoided when locating a wrapper cut position on the leaf.

In practice, it was found that the procedure for obtaining black andgray Pixel information by comparing the light intensity with a fixedvalue for determining black presented some difficulties, especially whenthe color of the leaf changed or the conditions of the light or cells350 varied. Consequently, in accordance with another aspect of thissystem a modified black signal is obtained by comparing the Pixel lightintensity with a controlled average voltage. This average voltage usesthe analog signals at line 402 for a majority of the Pixels. Bycomparing an analog Pixel voltage with an average voltage for priorPixels, a black signal is recorded when there is in fact a substantialblack condition compared with the operating conditions of the scannerand the color of the leaf. A circuit developed for obtaining thismodified black signal is schematically illustrated in FIG. 11. In thisfigure, the black modification conversion circuit 500 includes anautomatic gain control, or amplifier, 502 which amplifies the analogPixel voltage from line 402 and directs it to line 504. The automaticgain control or amplifier 502 is not needed in certain instances;therefore, it is enabled only when required by a gate 506. This gate hasinputs 510,512 connected by inverters 514, 516 with the output lines422, 424, respectively, of conversion circuit 420 previously described.If the previously described conversion circuit produces a white signal,a logic 0 is directed to gate 506 and amplifier 502 is not activated. Ifa black signal is created in line 422 the automatic gain control oramplifier 502 is deactivated and held deactivated for a time delayindicated by the block 520. This time delay retains the black signal fora set time, which is 0.1 seconds in practice. In other words, gate 506is deactivated whenever a white signal is created by circuit 420 and isheld deactivated whenever a black signal is received. This allows theautomatic gain control to be inactive when the sweep is mostly white,such as when there is no leaf or only a minor portion of the leaf isbeing detected by the sweep in the X direction. In this manner, theaveraging concept does not become over weighted in a white voltagedirection.

A differential amplifier 530 has inputs 532, 534 and an output 536 whichreceives the modified black signal. The voltage at input 534 isdetermined by the accumulated average of the Pixel voltage in line 504as averaged by circuit 540. This is a capacitor averaging circuit inpractice. The voltage of the capacitor averaging circuit is offsetdownwardly by an appropriate offset circuit 542. Consequently, thevoltage at the input 534 is the average of the Pixel voltages, butoffset downwardly for a reason to be explained later. To prevent thePixel average voltage captured in circuit 540 from being distorted bywhite signals and black signals, there is provided a white exclusioncircuit 550 which is adjustable as indicated by circuit 552. In a likemanner, a black exclusion circuit 560 is provided with an adjustmentcircuit 562. Circuit 540 receives no signals when gate 506 is disabledbecause of mostly white being recorded. The circuit 550 removes thosewhite areas which are not too large, such as a small hole.

The modified black output line 536 and line 424 are directed to NOR gate570 to produce a gray Pixel data in line 572 when there is no white ormodified black signal. During normal X sweeps across the leaf, theamplifier 502 is operative. It is only inoperative when there is aprolonged period of white. This removes from the averaging function thepredominantly white area of surface 300a surrounding the leaf beingscanned or the white area of a large hole. As shown in FIG. 12,averaging circuit 540 captures an average voltage indicated basically bythe line 580. This average voltage line excludes the black portions andwhite portions indicated by the legend OFF either by disabling amplifier502 or by exclusion circuits 550, 560. Offset circuit 542 offsets theaverage voltage downwardly to a level shown as line 582 which is thevoltage used as a comparison voltage for the Pixel voltage in line 532to determine a modified black output. By offsetting the average voltagedownwardly, only light intensities which are lower than the offsetaverage reference voltage in line 534 (line 582 of FIG. 12) will producea black signal. A white signal is produced in accordance with theconversion circuit 420 as previously described. By using the circuit asshown in FIG. 11 and graphically depicted in FIG. 12, a more accuratecolor profile in the X direction is obtained. As can be seen, theaverage voltage from a prior X sweep remains in the circuit 540 for thestarting point of the next sweep. In this manner, if a group of darkleaves are being scanned, black defects can be detected. In such aninstance, a fixed data voltage for detecting the black areas couldindicate the total leaf is black. Of course, it would be possible toadjust the fixed black data for darker leaves or changes in the responseof scanner 340 to overcome some of this difficulty; however, the circuit500 of FIG. 11 automatically makes appropriate compensations. FIGS. 9and 11 could be modified to give more than one shade of gray if needed.

As so far explained, the scanning system creates three output signalswhich are black, gray and white that are digital signals with a givenlogic indicating the existence of one of these colors for a particularPixel which has an X address for a given Y position. As the scan iscontinued, the color profile of the total tobacco leaf being processedis obtained by a series of signals indicating the shielding effect orthe light intensity of various identifiable locations or Pixels acrossthe total surface of the leaf and also across those portions of surface300a which are in the scanning pattern, but are not covered by a leaf.

GENERAL DATA PROCESSING (FIGS. 4, 5, 6 and 13)

As so far described, raw data is obtained for each Pixel or identifiablelocation during the scanning operation and this raw data is available atthe output lines of the structure shown in FIG. 8 or as modified by theshowing in FIG. 11. This data includes the color intensity of a givenlocation or Pixel and the address in the X direction across the surface300a. This information can be stored in sequence in standard READ/WRITEmemory through a normal direct accessing to the memory units used indigital computers. In other words, the raw data can be stacked insequence in the storage unit 70, shown in FIG. 4 which corresponds tothe direct access memory 220 of the control concept as illustrated inFIG. 5. This feature of storing data relating to the color intensity ofeach Pixel is schematically illustrated in FIG. 13 wherein the incrementline 469 is used to index a direct accessed memory after each Pixelvoltage signal is processed by the converter 420 and provided as awhite, black or gray signal. To allow time for settling of the Pixelinformation in lines 422 (536), 432 (572) and 424 a time delayarrangement can be provided. This is schematically illustrated as a timedelaying capacitor 469a. As so far described, Pixel data bits for all XPixels are stored in the direct access memory for each Y line orposition. Since each of the Y lines is stored, the Y address fromcounter 480 shown in FIG. 8 is not required. Indeed, with the raw databeing provided to the direct accessed memory, the X address would not beneeded since a particular location in memory would be assigned to eachof the Pixels both in the X and Y directions. As will be explained inaccordance with the illustrated embodiment of the disclosed system, theX address is required because not all the Pixels are stored. Inaddition, the X address would be valuable information for processing theleaf profile in most software arrangements. Digital computer 240 usesthe stored profile data in the memory unit to locate and arithmeticallyconvert cut coordinates as represented by block 240a in FIG. 13. Thisfunction block corresponds to the processing block 82 of FIG. 4. The cutcoordinates employed in the preferred embodiment are X1, X2 and Y whichare used in the cutter adjusting mechanism of the preferred embodimentas will be explained later. In other words, each cut position is locatedby three linear coordinates which are identified for the purposes ofdescription as X1, X2 and Y. These coordinates are provided as eight bitdigital words each of which will control a linear moving mechanism inaccordance with the magnitude of the digital number contained in theword. The digital computer also indicates the number of the cut and theparticular cutter used together with an ACCESS signal and a PROCESS stopsignal, as schematically illustrated in the general process chart ofFIG. 6. Essentially, the present system stores data relating to theprofile of the leaf and its defects in a manner which can be processedto locate the cut positions within the created profile image of theleaf. The leaf itself is not used in the location of the cutterpositions. The processing of stored data to locate the cut positions iswell within the general technology of the computer art when the memoryhas been loaded in accordance with the present system. Hereinafter,certain programming techniques will be discussed which simplify the cutlocation procedure used by the digital computer; however, various otherarrangements could be employed for the cut location to develop cutcoordinates for each cut.

TRANSITION CONVERSION (FIGS. 14 and 14A)

As so far described, raw data indicative of the color of each Pixel hasbeen created. This information could be used for controlling the cuttingequipment as hereinafter described by locating the wrapper cut positionsbased upon this raw data. However, in accordance with the preferredembodiment of the invention, the raw data is not required. As long asthere is raw data indicating white in the Pixels, the leaf has not beenreached or a hole or white defect is being viewed. The same is trueregarding a succession of gray or black raw data signals. Thus, toreduce the stored data necessary for constructing the profile or imageof leaf L, the present system employs data indicative of colortransitions. This transition data information can be obtained in avariety of ways between the output of surface shown in FIG. 8 and theinput to the storage memory. This involves a digital circuit interfacingthe scanner with the memory unit. A digital circuit for creatingtransition data and usable between the scanning circuit of FIG. 11 (FIG.8) and the memory units is illustrated in FIGS. 14 and 14A. Referringnow to FIG. 14, transition flip-flops 600-605 are reset when a pulse ofthe identified color is created. These flip-flops are set when a givencolor pulse is created. Consequently, the resetting of one of theflip-flops to create a logic 0 output indicates a color transition atthe Pixel being processed. Upon the receipt of a reset pulse, thetransition storing flip-flops 610-615 are clocked to produce atransition signal in lines 620-625 as indicated. On each φ2 pulse, thestorage flip-flops 610-615 are strobed back to the reset condition. Theinput lines of the circuit shown in FIG. 14 are the output lines of thepreferred embodiment circuit shown in FIG. 11. The output lines 620-625receive a pulse when a transition is made from one color to anothercolor at a given Pixel during an X sweep across surface 300a. If thetransition given both the "to" and "from" colors is to be used inconstructing the leaf profile for processing, the signals in lines620-625 could be used directly; however, in practice, it is onlynecessary to know that there is a transition to a given color such asblack, gray or white. Consequently, lines 620-625 are assimilated todetermine whether or not there is a transition to black, to gray or towhite. Various intermediate digital circuits could be used for thispurpose; however, in FIG. 14A OR gates 630-632 having outputs 633-635,respectively, are employed. Gate 630 has an output when there is atransition to black. In a like manner, gate 631 has an output when thereis a transition to gray, and gate 632 has an output when there is atransition to white. By using a digital system for determiningtransitions before the information is stored into the direct accessedmemory, a substantially reduced number of storage locations are requiredto provide the necessary information for the total profile of leaf L.When transitions are being used the X address appearing on line 472 ofFIG. 8 is required. This determines the X position at which a transitionis made to a given color. If the stem is being detected, there will be atransition to black at a given X position and then a transition to grayafter the stem has been passed. The same arrangement is used fordefects, surface variations and the edge of the leaf to determine theprofile of the leaf without using the raw data of all Pixels. Thecomputer would have access to the transition information; therefore, thecolor of any Pixel between transitions would be known from the storedtransition information. Consequently, transition data is used to savememory capacity. The transition circuitry shown in FIGS. 14 and 14A isin a digital circuit between scanning circuit 200 and direct accessmemory 202 as schematically shown in FIG. 5.

FACSIMILE DATA INTERFACE AND DIRECT ACCESS STORAGE THEREOF (FIGS. 15-20)

As indicated above, the raw data developed by the scanning operation canbe converted into transitions by an intermediate digital circuitrybetween the output of the circuits of FIGS. 8 or 11 and the actualmemory used for storing the data. Also included in this intermediatedigital circuitry for processing transitions instead of raw datadeveloped by the scanning process are digital transition transferringdevices of the type schematically illustrated in FIGS. 15, 16 and 17.These transfer devices direct the transition information or data tospecific memory locations, as schematically illustrated in FIG. 18.FIGS. 19 and 20 are schematic representations of the data actuallystored in the memory. If the transition data is indicative of the actualtransition from one color to another color, the data can be processed inaccordance with the digital circuitry illustrated in FIG. 15. In thiscircuitry, a sixteen bit accumulator 630 counts each transition pulsethrough a line 632. At the end of a scan, the reset line 454 resetsaccumulator 630. The output of the accumulator is illustrated as lines634, which include sixteen lines to read the stages of accumulator 630.This digital data is directed to the input of a data transfer chip 640having a sixteen bit output 642 and a data transfer terminal T activatedby lines 644 which is the EOS line 410. To provide a certain time delaybetween the EOS pulse and the indexing of the direct accessed memory,there is provided a device, such as one shot device 646 having an output648. The output indexes the memory to a next location into which thenext accumulator data from lines 642 is stored. In operation, for each Xsweep, the transitions are accumulated in accumulator 630. At the end ofthe sweep, the accumulated number of transitions is inserted into thememory and the memory is indexed. This continues for 512 sweeps in the Xdirection so that the memory has 512 sixteen bit words that are theaccumulated number of transitions for each of the several Y positions ofthe scanning operation.

To transfer the transition data, the transitions and the X addressthereof are directed to the inputs of a data transfer chip 650 havingsixteen outputs 652 and a transfer terminal T controlled by line 654. ORgate 656 receives a pulse at each transition which pulse is delayedslightly by a device, such as capacitor 657, to then transfer the inputdata to the output lines 652 of transfer chip or device 650. Anappropriate time delay 658 then allows indexing of the X memory unit bya signal in line 659. Thus, at each transition in the X direction, theaddress of the transition appearing in line 472 is transferred throughthe sixteen bit output 652 together with the type of transition. Thus,the X memory unit receives a transition and the Pixel address of thetransition.

The circuitry illustrated in FIGS. 16 and 17 is the same circuitry andhas basically the same numbers as the circuitry illustrated in FIG. 15.The difference is that the transition information is received from thenetwork illustrated in FIG. 14A. There is only three bits of transitioninformation or data, which data determine and record the type oftransition. Accumulator 630 of FIG. 17 still accumulates the same numberof transitions; however, the data being transferred through the sixteenbit lines 652 is indicative of the transition to a particular color andnot necessarily from which color the transition is being made. Thecircuitry shown in FIGS. 14, 14A, 16 and 17 is the preferred embodiment.This circuitry is interposed between the raw data scanning circuits ofFIGS. 8 and 11 and the direct accessing memory units. This isschematically illustrated in FIG. 18 wherein the direct access memoryunit for the Y information is called the "Y TAB" memory 660. Theaccumulated number of transitions at each of the Y positions is recordedand stored in sequence in this unit. In a like manner, the X informationincluding the type of transition and the Pixel address for thetransition is directed to the "X TAB" memory 662. This memory is indexedat each transition. Thus, the Y tab includes the accumulated number oftransitions for each of the 512 different Y lines being scanned by thescanner mechanism 200. The X TAB memory location includes the Pixel atwhich a transition is made by an X address and the type of transition.By using both the information and the X tab and Y tab direct accessmemory units, a profile of the leaf is stored for processing by anappropriate software arrangement for locating profile 30 withinlocations of the leaf L where there are no defects. The general outlineof the memory data in the Y tab and X tab storage units or memories areschematically set forth in FIGS. 19, 20, respectively.

PREFERRED DATA PROCESSING CONCEPTS (FIGS. 21-26)

As previously explained, the raw data or transition data, in thepreferred system, is transferred to the memory 200 for use by thedigital computer 240. The units 600, 602 of the preferred examplecorrespond to memory 200 of the control diagram of FIG. 5. The computerthen creates the cut locations and computes the cut coordinates for thevarious wrapper cuts to be made from leaf L. This can be done by avariety of software packages; however, in accordance with the presentsystem certain concepts have been developed for use in reducing thecomputer time and the software complexity. These basic concepts are setforth in FIGS. 21-26. Referring now to FIG. 21, leaf L is shown with theX and Y coordinates of the scanning grid. In the single illustrated lineX, it is noted that there is a transition to gray at the leaf edge, atransition to black at stem 10, a transition to gray after the stem andthen a transition to white at the opposite leaf edge. This type ofpattern continues through the total X sweep. Other transitions are alsoexperienced. After the leaf has been passed, the subsequent X sweeps donot provide further transitions. At the first X sweep, there is usuallyno transition. Thus, the Y tab storage as shown in FIG. 19 can indicatethe length of the leaf. Also, the Y tab can locate the X transitions fora given Y scan by pointing to a required X tab location. For instance,if the sixth Y line is being read, the Y tab indicates that the X sweepis between the 8th and 16th transition of the X tab. The X tab isscanned between the 8th transition and the 16th transition to give the Xsweep for the sixth Y line. If the 11th Y line is to be analyzed, the Xtab between the 50th and 58th transition provides the X sweep profile.This concept provides an easy access to the X sweep profile forprocessing by the computer by using transitions and accumulatedtransitions for locating information in the X tab. There is no need fora Y tab address although it is available, since the Y tabs are seriallystored data between 0-512. By taking this information, in accordancewith the preferred data processing system, a vector of the leaf outlineshown in FIG. 22 is created by analytical geometry. This outliningvector concept provides two X coordinates at a given Y line. The first Xcoordinate is a first transition from white and the second X coordinateis a last transition to white. Thereafter, the Y line is indexed a setnumber, such as 20-40 lines. The next Y line gives two additionaloutline X coordinates. These X coordinates are then noted and amathematical vector is created in the computer for comparing cut profile30 (in vector form) with the vectorized leaf outline to preventinterference with the leaf edge.

A dark area is located and recorded as shown in FIG. 23. Each of the Ylines is scanned for a transition to black and then for a transition togray or white. This indicates a black area on the leaf at each of the Ylines. To locate holes in the leaf, each of the Y lines is scanned for atransition to white and then to gray or black. For each hole, a maximumand minimum X and a maximum and minimum Y is recorded in the memoryprofile to outline a hole area or domain which is rectangular and is tobe avoided by a cut. A stem is located by noting a series of transitionsto black and then to gray along the stem. If these transitions arealigned in the X direction for a succesive number of Y positions, suchas 5-10 lines, it is noted that the stem has been located for storing ina memory unit of the computer. If the transitions do not align in the Xdirection over successive Y lines, the transitions are not the stem 10and are known to be either the diagonal veins or dark locationspreviously recorded. By vectorizing the outline of the leaf,constructing a rectangle or domain around the holes, noting the black ordark locations and locating the stem, there is sufficient processedinformation to locate the coordinates of a cut for a wrapper to avoidthe stem, dark areas, white areas and holes, as well as the outline ofthe leaf. FIGS. 22-25 disclose concepts used to facilitate the creationof a total leaf facsimile in X and Y coordinates and vectorstherebetween for location of proper cut positions. These are novelprocessing concepts and are not mathematical in nature.

In FIG. 26, the general programming approach to the preferred embodimentof the invention is illustrated. Basically these program steps whichcould be set forth in block diagrams are self-explanatory in nature whenconsidering FIGS. 19-25 and can be accomplished by various softwareroutines and techniques. The concepts of FIGS. 19-25 are novelprocedures which can be performed by software and used in the generalprogram of FIG. 26.

In the general program outline, after the X and Y tab have been storedin memory, steps (2)-(6) create the vector outline of the leaf as shownin FIG. 22. Steps (7)-(9) provide the hole domain as shown in FIG. 25.Steps (10) and (11) construct the stem for the leaf which is to beavoided in the cut position. By an optimizing subroutine, a safe line isconstructed adjacent both sides of the stem as shown in step (12) whichsafe line is to be avoided in positioning a cut profile 30. In step(13), the vectorized profile 30 is mathematically positioned at one endof the leaf and adjacent the stem safe line. In step (15), if there isan intersection of the edge vector as tested in step (14), the cutprofile is shifted along the safe line a given amount and step (14) isrepeated. If the outline is avoided as indicated in step (16), theexistence of holes or other unwanted defects is determined. If there areholes or other defects not wanted in the profile 30, it is then shiftedin the Y direction along the safe line adjacent the stem as in step (17)until a position is located wherein there is no hole location or leafoutline intersection. At that time, as indicated in step (18), the blackarea and any minute holes in the tuck or head are tested as indicated instep (18). As indicated in step (19), if the tuck or head has blackareas or other small defects the shifting process continues until thecut profile vectors reach the opposite leaf vector outline or a cutlocation has been determined. If the outline has been reached without acut location, a new safe line is constructed as indicated in step (20)which is offset (in the X direction) and spaced from the previous safeline. The process is repeated until whole leaf half has been exhaustedas indicated in step (21) or a cut location has been obtained. If thecut location has been obtained and meets the parameters previouslydiscussed, the X and Y position of a point on the profile 30 and theangle of this line with respect to the Y axis is recorded and thenecessary X1, X2 and Y coordinates are calculated and stored forsubsequent outputting to the programmable controller to use forsubsequent cutting. The angle φ occurs because the stem may not bealigned in a Y line which will give an angled safe line. This angle issmall since the leaf L is aligned as best shown in FIG. 21 with the stemas vertical as practical. The type of coordinates which are required arecorrelated with the type of movement mechanism being used for thecutting device so that the mathematics for creating coordinates willcreate an output that controls the position of the cutting in accordancewith the selected cut position originally identified as X, Y and φ. Inother words, the X1, X2 and Y coordinates are calculated from the X, Yand φ coordinates to correspond with the exact type of cutting mechanismused to adjust the leaf supporting surface or cutting surface withrespect to the cutter as will be explained later. This mathematicalrelationship is easily programmed into the computer. This function issteps (22) and (23). After a cut position has been located, as indicatedin step (24), the vectors used in the profile 30 are added to theoutline vectors of the leaf to change the profile of the leaf vectors byexcluding from future consideration the previously selected cuttingposition. Thereafter, as indicated by step (25), the process from step(13) is repeated to locate a next cut or cuts on the half of the leafbeing so far processed. After all the cuts have been located on one halfof the leaf, the steps commencing at step (12) are repeated for thesecond half of the leaf. Thereafter, the program has been completed andthe computer will create a ready or access signal as indicated by step(27). This can be an output flip-flop or other arrangement to indicateto the programmable controller that the cut coordinates have beendetermined for a particular leaf being scanned and processed. Asindicated in steps (28)-(30), the computer then waits until theprogrammable controller 210 indicates that it is ready to receive thecut coordinates, the cutter and cut numbers from the digital computerfor use in subsequently cutting cigar wrappers from leaf L. Of course,other programming concepts could be used in practicing the presentsystem, but the information illustrated in FIGS. 18-26 is preferred andinvolves certain novel concepts which reduce the software involved,decrease the cycle time for the total software program and reduce thechances of any error in the location of the cut positions for variouscigar wrappers from a given natural tobacco leaf L. Basically, theoutputted coordinates X1, X2 and Y are binary words that are transferredfrom the digital computer to the programmable controller for controllingthe cut location determined by the computer. The digital informationfrom the computer is then used directly for the location of the cutpositions in a manner to be described later.

POST SCANNING PROCESSING MACHINE COMPONENTS (FIGS. 27-39)

Referring now again to FIG. 5, the apparatus for performing the scanningand cutting process to remove cigar wrappers from leaf L includesseveral machine components which are generally labeled in this controlconcept diagram and are shown in detail in FIGS. 27-39. Essentially, theprogrammable controller 210 receives coordinates X1, X2 and Y for eachof several cuts to be taken from the leaf together with the propercutter and the sequence of cuts to be made. This information is receivedin digital form with the three coordinates in the preferred embodimentbeing binary representations of translation or linear movement.Programmable controller 210 uses the binary coordinates and the digitalinformation to control the various mechanisms including the scanningmechanism previously described to process the leaf so that the computeritself can be used primarily for determining the cut positions basedupon direct stored memory information indicative of the profile or imageof the leaf after scanning by mechanism 200. The machine cyclescontrolled by the programmable controller are in accordance with commonmachine control techniques; therefore, the mechanisms will be describedin accordance with their structure and functions.

Scanning mechanism 200 has been previously described in connection withthe structure of FIG. 7; therefore, the detail of mechanism 200 is notto be repeated. Details of the other machine components will hereinafterbe set forth in an embodiment of the invention to perform the desiredfunctions; however, it is appreciated that other embodiments could beused. In some instances, the disclosed embodiments illustrate novelfeatures which were specifically developed for the present system andwhich will be the subject of certain claims on the inventive aspects ofthe present application.

LEAF TRANSFER MECHANISM

As shown in FIG. 27, the leaf is transferred from surface 300a of belt300 by a somewhat standard vacuum type transferring arrangement whichincludes an arm 700 supporting a head 328 which includes a lowerperforated surface generally parallel to the upwardly facing surface300a of belt 300 in the transfer area of the scanning arrangement asshown in FIG. 7. For the purposes of simplicity in FIG. 7, arm 700 whichdirects either air or vacuum to head 328 is shown to be generallyhorizontal of belt 300; however, as shown in FIG. 27 the arm in thetransfer position is essentially transverse of the belt 300. Head 328 isshifted by arm 700 between a first leaf receiving position and a secondleaf releasing position. Arm 700, in the illustrated embodiment, isturned by lever 700a about axis a by a cylinder 700b mounted on fixedtrunnion 700c. The first leaf receiving position of arm 700 and head 328is located by an adjustable stop 704 coacting with surface 705 ofextension 706. A second adjustable stop 702 coacts with surface 708 ofextension 706 to locate head 328 in the leaf releasing position. Limitswitches at these stops will indicate when the transfer head 328 carriedby arm 700 is in either of the two positions. Appropriate valving willdirect either air or vacuum to the perforated under surface of head 328for lifting a scanned leaf from belt 300 or depositing a leaf onto thecutting table. The belt must be in a known position with respect to thescanning operation when the leaf is removed from the belt. In thismanner, the position of the leaf on the transfer head 328 is correlatedand oriented to the Pixels scanned during the scanning operation. Thiscan be done by stopping belt 300 at a fixed number of encoder pulses inline 312 after the stop scan signal in line 454 of FIG. 8. Other systemscould be developed for assuring that the leaf is captured on head 328 indirect correlation to the X and Y scanning lines of the scanningoperation. Irrespective of the technique used, leaf L is picked up bytransfer head 328 in a fixed position with respect to the prior scanningoperation which maintains the positional orientation with respect to theprior scanning of the leaf. Adjustable stop 704 allows small adjustmentsin the pick up position. Thereafter arm 700 is shifted by cylinder 700bagainst stop 702 which transfers the leaf held against the lower surfaceof head 328 to a fixed, known position with respect to platen 710 havingan upper surface 712. Small adjustments can be made by stop 704. Leaf Lis deposited onto platen 710 in a known position with respect to theprior scanning operation. Platen 710 includes lower guide wheels 714 anda side locator hole 716 into which a pin 720 or 722 is protruded by anoperator, such as a solenoid 724, 726, respectively. In the leaftransfer position of platen 710, as shown in FIG. 27, pin 720 is in hole716 so that the platen is in a fixed, known position. Transverselyextending support rails 730, 732 allow movement of platen 710 byappropriate means schematically represented as cylinder 736 having amovable rod 738. Carried upon the upper portion of platen 710 is acutting table 750 onto which the leaf is transferred when arm 700 isagainst stop 702. Cutting table 750 is in the oriented fixed position asshown in FIG. 27 for receiving the leaf. By coordination of the table750 and the pick-up position of leaf L from belt 300, the leaf isdeposited by transfer head 328 onto table 750 in a coordinated, orientedposition with respect to its previous scanned position. The table 750 issupported on platen 710 which is held in the leaf receiving position bypin 720 entering guide slot 716. The scanned leaf which produced thedesired profile in a stored memory unit is transferred onto the orientedtable 750 by applying a vacuum to the cutting table and pressurizing orevacuating the head 328. This is a known transfer arrangement fortobacco in the cigar making industry. As best shown in FIGS. 32-35,cutting table 750 includes an upper nylon plate 752 having a pluralityof parallel arranged openings 752a which have a diameter ofapproximately 0.04 inches. This plate, except for holes 752a, is acutting board produced by Boston Cutting Die Company and is formed fromhard nylon with a trademark WOGULON. Upper plate 752 has an uppercutting surface 752b. A second hard nylon plate 754 is formed with aplurality of generally parallel grooves 754a that correspond withopenings 752a and have a thickness of about 3/16 of an inch. Inbetweenthe grooves the upper and lower plates 752, 754 are secured together forcutting rigidity. Grooves 754a do not extend to the periphery of cuttingtable 750 and they form a plenum chamber communicated with the openings752a to allow a vacuum from manifold 756 to be applied to all grooves754a and thus to the openings 752a at surface 752b. Another manifold756a may be positioned at the opposite end of grooves 754a. In theillustrated embodiment shown in FIG. 35 a vacuum is applied to manifold756 so that a vacuum can be directed to the upper surface 752b ofcutting table 750 for clamping a transferred leaf onto the upper cuttingsurface for performance of the cutting operation. To remove a spent leaffrom the surface 752b after the cuts have been made air pressure can bedirected to grooves 754a by line 758 communicated with manifold 756a. Ofcourse, a single manifold could be used at one end of the grooves witheither vacuum of air being applied selectively to the same manifold. Themanifolds are positioned generally outside the cutting area of cuttingboard or table 750 so that the manifolds do not adversely affect therigidity of the board or table for the cutting operation. By providingthe parallel grooves to direct pressure to the surface 752b of thecutting board or table 750, the cutting table is essentially a rigid,hard nylon cutting structure. As can be seen, vacuum holds the leaf ontothe cutting board in the position to which it is transferred by transferhead 328. This position is oriented and coordinated with the scanningoperation so that the leaf is in the desired position for adjustmentwith respect to a cutting mechanism to be hereinafter explained.

CUTTING MECHANISM

Before describing the system for adjusting table 750 to the desiredposition for cutting, it is desirable to understand the preferredembodiment of the cutting mechanism 800. This mechanism is best shown inFIGS. 29-31 and includes a pancake cylinder 802 having a pneumatic inlet803 and a piston 804 movable against a lower abutment or shoulder 806and spring biased away from the abutment by a plurality ofcircumferentially spaced machine springs 807. Of course, an appropriateseal 808 is employed to seal the cylinder and piston. As illustrated,four separate cookie cutter type dies 810a-d are provided on piston 804.In practice, it is conceivable that only a left hand and right handcutting die will be used. By showing four separate cutting dies, thesystem can cut two separate sized wrappers from each half of the leaf byan appropriate signal from the computer to the controller. This isuseful when a large wrapper is being cut from the natural tobacco leafand it is found that a smaller wrapper could be cut from availablenon-defected areas instead of one or more larger wrappers. The use ofmore cutting dies would increase the productivity; however, it is notnecessary for the general understanding of the system. Basically, thecomputer commands the programmable controller 210 where to cut and whichcutter 810a-d to use. Normally, the cutters 810a and 810c would be usedto produce wrappers having the same general shape, but cut from oppositesides of the leaf so that they would be opposite profiled wrappers foruse in different cigar making machines. The cutters themselves are fixedin position and the table 750 adjusts the tobacco leaf carried thereonto the proper cutting position. In the illustrated system, cylinder 802is mounted on a fixed machine frame 814 having a lower abutment surface815. A plurality of slidable guide pins 816 allow reciprocal movement ofcylinder 802. A mechanism 820 is provided for shifting cylinder 802between the upper cutting position with the cylinder against surface 815and a lower position for transferring the cut wrapper to a subsequentapparatus for storage and use. Mechanism 820 could take a variety offorms; however, in the illustrated embodiment this mechanism includes alimit switch 822 to control the vertical position of cylinder 802. Apinion 821 driven by an appropriate motor 823 coacts with rack 824secured on cylinder 802 to drive the cylinder between the upper cuttingposition and lower transfer position. The basic location of these twovertical positions is generally controlled by an appropriate mechanism,such as cams 826, 828 coacting with limit switch 822. During the cuttingoperation, cylinder 802 is abutting against surface 815 to rigidify thecylinder. During the wrapper transfer operation, rack 824 shiftscylinder 802 downwardly.

Cutters 810a-810d are located on piston 804 and are essentially the samein structure, except the size and/or shape of the cutters are somewhatdifferent to create wrappers having the desired shape. It is appreciatedthat any number of cutters could be mounted on the piston and can beselectable for the actual cutting operation. Since each of the cutters,except for shape, is the same, only cutter 810a will be described indetail. This description will apply equally to the other cutters mountedon the piston. Indeed, only one cutter may be provided in someinstances. Cutter 810a is fixed to a cutter block or support block 830slidably received upon a plurality of dowl pins 832. Appropriatelyspaced machine bolts 834 include machine springs 836 which hold block830 rigidly against the undersurface of piston 804. A slot 840 extendsacross the back surface of block 830 in a position generally parallel tothe wrapper cutter 810a. Opposed cams 842, 844 having a cut supportingupper surface 846 are movable by solenoids 850, 852 under the control ofa signal received by lines 854, 856. If a particular cutter is selectedto make the cut being processed by the mechanism as shown in FIG. 27,solenoids 850, 852 shift cams 842, 844 inwardly until surfaces 846project block 830 outwardly on dowl pins 832. In this fashion, surfaces846 support cutter 810a in a downwardly extended active position withrespect to all other cutters which remain in a retracted inactiveposition. Thus, only cutter 810a will cut when piston 804 is forceddownwardly by pressure from inlet 803 against the action of machinesprings 807. The particular signal indicating the cutter to be usedcontrols the signal within lines 854, 856 to select any one of thecutters supported on piston 804. When piston 804 is forced downwardlyagainst table 750, the extended cutter cuts according to the adjustedposition of the table with respect to that activated cutter. As thepiston 804 is retracted by exhausting air from line 803, the cigarwrapper cut by cutter 810a is held within the cutter and pulled from thesurface of leaf L. To assist in this action, a vacuum, from a source notshown, may be directed to the inside or the interior of the cutter. Withthe wrapper cut and within the cutter, cylinder 802 can be shifteddownwardly after platen 710 is retracted from the cutting position. Thewrapper is now ready to be transferred for subsequent processing.

TRANSFER OF CUT WRAPPER

Referring now to FIGS. 27, 28 and 32, a cut wrapper is transferred tothe vacuum table 870 indexable about center shaft 871. The upper surface872 of the table is perforated at least in selected areas. A plenumchamber below surface 872 can apply a vacuum to the surface inaccordance with standard practice. Of course, certain areas of theplenum could be formed to create surface vacuum, air pressure oratmospheric pressure to assist in wrapper transfer. When cylinder 802 ismoved downwardly by rack 824, cutter 810a having a cut wrapper thereinis positioned onto surface 872. Thereafter, air pressure can be appliedto the cutter profile or the vacuum itself in the table 870 can draw thecut wrapper from the cutter onto surface 872. Cylinder 802 is thenretracted upwardly for the next cutting cycle and table 870 is rotatedor indexed to one of the standard wrapper storage bobbins 880a-880d.Each of the bobbins receives a cut wrapper from only one of the cutters810a-810d. The standard wrapper storage bobbins 880a-880d each includesa porous belt 882 on a storage reel, a vacuum transfer and holdinghousing 884 and a storage bobbin 886, as shown in FIG. 28. After awrapper cut has been made, the wrapper is deposited onto table 870 whichis indexed to the desired position where a vacuum is applied to belt 882at least adjacent the inlet end of housing 884. The cut wrapper istransferred to belt 882 and held onto the belt until it is reeled ontobobbin 886. During the indexing of table 870 and storage of a cutwrapper the next cutting operation is being performed by mechanism 204.

This wrapper removal procedure follows each cut and is repeated untilall cuts are made in leaf L. The wrappers are all stored on theappropriate bobbins 880a-880d. Platen 710 carries table or cutting board750 back to the leaf receiving position shown in FIG. 27 where the table750 is pressurized by line 758 and air jets 890 blow the cut leaf offthe table into an appropriate repository. This removing mechanism usingjets 890 is schematically illustrated as block 208 in FIG. 5.

CUT LOCATING MECHANISM

After the cut positions have been located and identified as threedigital words (X1, X2, Y), these words or coordinates are used to locatethe cut positions of cutting board or table 750. To perform the movementof table 750 to the various cut positions platen 710 carries table 750to the position shown in FIG. 32. During movement of the platen to thecutting position, or after the movement has been completed, table 750 isshifted, rotated and otherwise moved to align leaf L directly below theselected cutter, which for illustrative purposes has been indicated tobe wrapper cutter 810a, in the cut position identified by coordinatesX1, X2 and Y. This shifting of table 750 is done by converting the threedigital words (X1, X2, Y) corresponding to the proper cut position intothree coplanar translation movements of the table 750 which duplicatethe X, Y and φ cut position previously described. In accordance with anovel aspect of the present system, the three linear movements, whichcould be coordinates X, Y and φ as shown in FIGS. 36A, 36B, are obtainedby linear translation distances determined by the binary number of thethree separate words X1, X2 and Y. Of course, according to the type ofmoving mechanism used for table 750, the translation magnitude wordswill vary. The translation distances cause table 750 to move so that thelocated X, Y, φ position of leaf L is aligned with the selected cutter.In accordance with this aspect of the system, no rotary movement isrequired for table 750. The angular movement corresponding to φ isobtained by differential linear translation movements of two linearmotors 900 and 902 fixed on surface 712 of platen 710. The details ofthese motors will be explained in connection with FIGS. 37-39. Themotors 900, 902 and 904 each carry a movable element 910, 912, 914,respectively, which are translated a distance controlled by the binarymagnitude of digital words X1, X2 and Y, respectively. These words aredirectly correlated with the movement of elements 910-914 to locatetable 750 in the cut position as determined by the scanning andselecting process previously described. The location of table 750, inturn orients leaf L carried in a known relation on surface 752b. Ofcourse, various systems could be used for movement of table 750, some ofwhich would include a rotary action. It has been found that by using thetranslation action developed in accordance with the present system, thedifficulties encountered in rotating table 750 through an angledetermined by a cut coordinate is avoided. As previously discussed, thecut position can be at an angle with the Y axis since the stem of theleaf may be at an angle or the leaf may be positioned on belt 300 at aslight angle. For that reason, the preferred system requires a certainamount of angular movement which is obtained by differential translationof the two sides of table 750 by motors 900, 902.

The lower surface 754b of the lower nylon plate 754 forming table 750rides along and is supported by an anvil 920 having an upper tablesupport surface 922 which is parallel to lower surface 754a. Anvil 920supports table 750 during the shifting action to locate the various cutpositions. To move table 750 into the cutting positions there areprovided two generally parallel slots 930, 932, as best shown in FIGS.34, 36A and 36B. These slots are milled or otherwise provided in thelower nylon plate 754 of table 750 and are generally parallel inrelationship and extend in the X direction of table 750. Between thesetwo slots there is provided a generally orthogonal slot 934 which is atan oblique angle with slots 930, 932 which angle, in practice, is 90° sothat it is aligned with the Y axis of table 750. The X and Y axes oftable 750 define a grid corresponding to the scanned grid of the leaf.Of course, the grids are not marked on the scan surface or table sincethey are correlated by the transfer of leaf L. Pins 930 a, 932a, and934a are slidably received within slots 930, 932, and 934, respectively,so that movement of the pins in a direction generally transverse to theslots will orient table 750 for proper positioning of leaf L at theproper cutting position with respect to the selected cutter, illustratedas cutter 810a. Pins 930a, 932a move in straight lines on platen 710which lines are parallel to the Y direction of table 750 when the tableis in the leaf receiving position shown in FIGS. 27 and 34. Pin 934a ismovable in a straight line on platen 710, which straight line isparallel to the X direction of table 750 when the table is in the leafreceiving position shown in FIGS. 27 and 34. In the illustratedembodiment, as best shown in FIG. 34, slots 930, 932 are aligned and onopposite sides of slot 934 and pins 930a, 932a and 934a are all alignedin a direction corresponding to the X direction of table 750 when thetable 750 is in its leaf receiving position shown in FIGS. 27 and 34.Pins 930a, 932a are directly supported upon the movable elements 910,912, respectively, of motors 900, 902, respectively. Consequently,reciprocation of elements 910, 912 causes reciprocation of pins 930a,932a to reciprocate table 750 in the directions indicated by the arrowsin FIG. 34. Pin 934a is carried by a block 936 slidably received withinslot 938 of anvil 920. A drive cable 940 with a series of pulleys 942connect block 936 drivingly with an anchor block 944 supported onelement 914 which is reciprocated by the third translating motor 904.Slot 938 is orthogonal to the rest position of slot 934 and parallel tothe direction of slots 930, 932. Thus, translation of element 914 causespin 934a to move in the direction indicated in FIG. 34 a distance equalto the translation distance of element 914.

As three digital words are received, they indicate in binary languagethe amount of translation of the elements 910, 912, 914. The wordsactually provide the translated position of elements 910-914 for the cutposition. If the motors 900-904 start from a zero position, the actualword gives the amount of translation. If the elements are in anintermediate position the words indicate the corrective amount oftranslation. Motors 900-904 may be at a prior cut position and they neednot retract to the zero position to go to the next cut position. Inpractice, table 750 is in the zero positions of X1, X2 and the middleposition of Y when in the cut receiving position shown in FIGS. 27 and34. The binary words X1, X2 and Y are converted into movement of table750 by the coaction between slots 930-934 and pins 930a-934a. In FIG.34, table 750 is in the rest or leaf receiving position, which is theposition used in accepting a leaf when platen 710 is in the leafreceiving position shown in FIG. 27. After the leaf has been receivedand vacuum has been applied through line 757 of table 750, the leaf isheld in place and the programmable controller receives cut coordinatesX1, X2 and Y which control the translation position of elements 910-914controlled by motors 900-904, respectively. In this manner, the table750 carrying the leaf is adjusted with respect to the cutter 810a, whichcutter is then forced downwardly against table 750. When this happens,the upper surface 922 of anvil 920 supports the table to create areactive force against the table to facilitate the cutting action. Thus,the movement of the cutting board or table 750 into the proper cutposition is by the movement of three pins which are translated, but donot support the table in a vertical direction. The actual cutting forceis against anvil 920 with upper portion 752 of table 750 being theactual cutting member. In this manner, table 750 has a low weight anddevelops low inertia forces. Pins 930a-934a need not have a heavyconstruction to withstand the subsequent cutting forces. Thus, the pinsdevelop low inertia forces. In practice, a head is provided on themoving pins 930a, 932a to coact with a retaining structure adjacentslots 930, 932 to hold table 750 in the horizontal position as it isshifted. As previously mentioned, after the cut has been made thewrapper is removed by the cutter and platen 710 moves to a positionclearing cylinder 802 so that the cylinder can be moved downwardly totransfer the cut wrapper onto vacuum table 870 for subsequent indexingto one of the wrapper bobbins 880a-880d. When the cut is made by cutter810a, table 870 is indexed to wrapper storage mechanism 880a where thecut wrapper is transferred to storage element or bobbin 886 forsubsequent loading into a cigar machine in accordance with standardcigar making practice. As shown in FIG. 37, the top of the pins 930a,932a can include a head 950 held within the respective slots by anappropriate plate 952. Other arrangements, such as a T-slot and head,could be used to hold table 750 onto the moving pins for movementtherewith. The actual cutting action takes place against the uppersurface 922 of anvil 920.

FIG. 36A shows an example where table 750 has been shifted to a cutposition with X1 greater than X2 and Y shifted to the left, as viewedfrom surface 754a. Another example is shown in FIG. 36B with X2 greaterthan X1 and Y shifted to the right as viewed from the under surface754a.

A variety of structures could be used to translate elements 910-914 in amanner controlled by digital signals; however, one mechanism foraccomplishing the conversion between digital coordinates in binary wordsand translation of the movement elements is a binary motor concept. Thisconcept is used in motors 900-904. Since each of these motors isessentially the same, only motor 900 will be described in detail andthis description will apply equally to binary motors 902 and 904. Asshown in FIGS. 37-38, motor 900 includes a series of cylinders 960-1 to960-8 having internal double acting pistions 962-1 to 962-8. Thesecylinders are connected together so that an eight bit binary word usedto control the pressure in each of the cylinders will translate element910 a distance corresponding to the numerical value of the binarynumber. Of course, the binary number could include various number ofbits. A variety of structures could be used for interconnecting thepistons and cylinders; however, in the illustrated embodiment thecylinders are connected together in the following sets: 960-1 and 960-2,960-3 and 960-4, 960-5 and 960-6, and 960-7 and 960-8. Piston 962-1 isfixed at one end of motor frame 963. The pistons are interconnected inthe following sets: 962-2 and 962-3, 962-4 and 962-5; 962-6 and 962-7.Piston 962-8 is connected to the movable element 910 by shaft 964.Successive pistons have strokes which vary in binary fashion, i.e. varyas a factor of 2. In the illustrated embodiment as set forth graphicallyin FIG. 39, the first cylinder has a stroke of 0.04 inches. Each of thesuccessive cylinders has strokes which are factors of 2 of this stroke.A support and bearing rod 966 extends the complete length of motor frame963 and passes through the respective cylinders as shown incross-section in FIG. 38. This rod allows translation of the variouscylinders in a direction parallel to the stroke of the pistons withinthe cylinders. To support the other side of the cylinders, there isprovided a fixed rail 988 supported on a fixed stand 989. The cylinderhousing includes upper and lower guide plates 990, 992 which slide alongthe fixed rail 988 to support the cylinder housings in the verticaldirection. Rod 966 controls the horizontal movement of the motor. Tomove the pistons in the respective cylinders, there is provided a doubleacting valving unit 970 including valves 965-1 to 965-8 schematicallyshown in FIG. 39. These valves are controlled by the binary logic on bitNo. 1 to bit No. 8 of the binary word indicating the amount oftranslation for element 910. Flexible conduits 972 are the ON or the YESfluid conduits, whereas the flexible conduits or couplings 974 are theOFF or NO conduits. A selected binary word indicating the movement ofelement 910 controls the valves shown in FIG. 39 to control fluidpressure to the various cylinders shown in FIG. 37. By the illustratedexample, the amount of movement of element 910 corresponds to themagnitude of the binary number in the 8 bit word directed to the valvingunit 970. Element 910 is translated in accordance with the binary wordused as one coordinate (X1) in locating the cut position of table 750with respect to cutter 810a. The operation of the three motors 900-904(X1, X2 and Y) duplicates the located cut position provided as threebinary words (8 bits). The three motors are moved in accordance with therelationship of the pins and grooves needed to locate the upper surfaceof table 750 for cutting. Primarily, the cut locating mechanism involvesthree translating devices which are translated in accordance with thedesired ultimate position of leaf L, as indicated by binary numbers ordigital information.

CONCEPTUAL AND APPARATUS MODIFICATIONS AND ILLUSTRATIONS (FIGS. 40, 40AAND 41-43)

Referring now to FIG. 40, a conceptual variation of the system as so fardescribed is illustrated. In this conceptual concept, an appropriatelight 1000 passes light rays through a leaf support member 1002 ontowhich a leaf L is supported. The support member is translucent ortransparent so that light rays are transmitted through the supportmember to an appropriately positioned one way mirror 1004 which reflectsthe image of the leaf in oriented fashion onto the display screen 1010.The displayed image 1020 is intersected by light images from projectors1022a, 1022b, and 1022c which project images 1030a, 1030b and 1030ccorresponding to the cut profile images shown in FIG. 3 through mirror1004 onto screen 1010. Servo mechanisms 1040a, 1040b and 1040c arecontrolled by a unit 1050 having three sets of manually manipulatedelements 1060a-c, 1062a-c and 1064a-c. For each of the sets of elements,there is provided a blanking button 1070, 1072, 1074, respectively. Unit1050 also has an enter data button E. In practice, elements 1060a,1062a, and 1064a are adjusted until the image or outline 1030a is in aposition avoiding all defects in the image 1020 of leaf L. This movementof elements on the face of unit 1050 controls servo mechanisms 1040a-cby an appropriate interconnect indicated as line 1055. After the firstoutline is properly positioned at the X, Y and φ coordinates of line Rand point P thereon, the knobs for controlling the next profile 1030bare manipulated until the image is in the proper position to createcorresponding X, Y and φ coordinates. Thereafter, the third image 1030cis manipulated to obtain a cut position. If a third cut can not be madein a non-defect area of the leaf image 1020, the blanking button 1074 isactuated to indicate that no cut is possible for this third image. Thesame type of unit 1050 may be used on the other half of the leaf imageto manually manipulate the cut profiles onto the visually displayedleaf. Thereafter, the information determined by the position of thecontrol elements on unit 1050 is transmitted as X, Y and φ to an analogto digital converter 1080. This digital information is arithmeticallyconverted to coordinate forms acceptable by programmable controller 210so that the data provided by converter 1080 to programmable controller210 is the coordinates X1, X2 and Y as used in the preferred embodimentof the system as so far explained. The system shown in FIG. 40illustrates a remotely positioned image determined by the leaf itselfinto which is fitted the cutting profiles. The information generated isconverted to digital information which is indicative of translation thatcontrols the operation of motors 900, 902 and 904 in the illustratedembodiment of the invention. Referring now to FIG. 40A, the system shownin FIG. 40 is modified to have a light source 1100 which shines uponleaf L and transmits the front lighted image to the screen 1010 throughan optical system 1102. Otherwise, the system of FIG. 40A operates inaccordance with the general system shown in FIG. 40.

FIG. 41 schematically illustrates a modified mechanism for processingnatural tobacco leaf L. This mechanism includes an indexable turret 1200movable between scan, cut, unload and load positions and having foursupporting platens 1210, 1212, 1214 and 1216. Each of these platens issimilar to platen 710 and movably supports cutting boards 1220, 1222,1224 and 1226 similar to table 750. The cutting tables each include avacuum surface for holding leaf L onto the cutting table as previouslydescribed in the preferred system for processing the natural leaf. Ascanning head 1230 is used to scan the leaf L in the X direction as thecutting table is indexed to the Y direction. As shown in FIG. 43, theleaf L can be illuminated from the front by a plurality of light sources1232. Of course, light could be positioned under the cutting board 1220in the scanning position. Turret 1200 is indexed to bring the scannedleaf into the cut position. At that position, the cutting table isindexed and rotated to the various cutting locations and the cuttingprocess is performed as previously described. To transfer the wrapper toa transfer device or vacuum conveyor, platen 1212 as shown in thecutting position, can be indexed to the left to allow transfer of a cutwrapper, as previously described, onto a vacuum belt or conveyor 1234.Thereafter, turret 1200 is indexed to the unload position and air jets1240 blow the cut leaf from cutting board 1224 as vacuum is releasedfrom the cutting table. Following this action, turret 1200 is indexed tothe load position where leaf L is spread onto the cutting table 1226.Each of these processes is being performed simultaneously; therefore,during each index, each of the functions previously described isperformed at the various illustrated locations. This mechanismillustrates the concept of cutting the leaf on the scanning surface.This does not require reorientation of the leaf onto a new surface asused in the preferred system.

Referring now to FIG. 42, a conceptual aspect of the present inventionis illustrated. In this aspect, a grid A provided on a first member 1300is fixedly positioned with a grid B on a member 1302. During thescanning operation, the light intensity of the various elements orPixels on grid A are recorded. Thereafter, the leaf is transferred alongthe direction indicated by the arrow to grid B. This transfer orientsthe leaf onto grid B in accordance with the scanning system previouslydescribed with respect to grid A. Thus, by utilizing the scanned concepton grid A this concept applies equally to grid B onto which the leaf isoriented. Member 1302 can then be shifted with respect to cutter 1304 tocut a wrapper based upon the position of grid B whereas the scanning hasbeen accomplished with respect to grid A. This is the concept used inthe preferred system of the present invention and is shown in FIG. 42for illustrative purposes only. Also, this new system can cut differentsized wrappers wherein the prior manual system cut only a single sizedwrapper from a leaf half.

Having thus defined the invention, it is claimed:
 1. A digital devicefor storing into a memory unit a positionally oriented digitalrepresentation of the outline and distinct light detectable surfacevariations of a natural tobacco leaf having two generally parallel largearea surfaces with light detectable surface variations, said apparatuscomprising: means for supporting said leaf in a spread condition on asurface; means for illuminating said leaf to create an emitted lightintensity pattern of selected locations on said surface indicative ofthe non-existence of a leaf, the existence of a leaf and light intensityof the surface of said leaf; measuring the emitted light intensity atsaid selected locations; means for creating a first digital signal whensaid light intensity at a location is above a selected first level;means for creating a second digital signal when light intensity at alocation is below a selected second level; means for creating a thirddigital signal in the absence of said first and second signals; scanningmeans for reading a succession of said measured light intensities forlocations in a given path across said member in a first direction; meansfor shifting said path in a second direction generally orthogonal tosaid first direction; means for creating a digital address for each ofsaid locations; means for creating a transition digital signal when afirst, second or third digital signal for one location changes toanother signal in a next successive location; means for transmittingsaid digital transition signal identifying said other signal and adigital address of said one location to said memory unit.
 2. A digitaldevice as defined in claim 1 including in combination said memory unit;means for accumulating the number of transition signals during saidsuccessive paths; and, means for storing in a first area of said memoryunit the total number of transition signals accumulated in eachsuccessive path in said memory unit, said total number includingaccumulated transition signals in prior paths.
 3. A digital device asdefined in claim 1 including means for storing in an area of said memoryunit, in succession, each of said digital transition signals and saiddigital address for each location of said transition signals.
 4. Adevice for creating a series of digital signals indicative of theprofile and certain surface variations of a natural leaf, said devicecomprising: means for supporting said leaf in a spread condition on amember; means for sensing light emitted from a succession of locationson said member; means for scanning said emitted light at said locationsin succession in a given path and then in successive paths parallel tosaid given path until the light emitted from all locations on saidmember and covered by said leaf are scanned; first means for creating afirst digital pattern signal when the light intensity of the emittedlight from a scanned location is above a preselected level; second meansfor creating a second digital pattern signal when the light intensity ofthe emitted light from a scanned location is above a selected level lessthan said preselected level; means for creating a third digital patternsignal in the absence of said first and second digital pattern signalsfor a scanned location; means for creating a transition signal for alocation when a prior digital pattern signal is different from a scanneddigital pattern signal; means determining the pattern signal to whichsaid transition signal is made and means for recording said transitionand determined pattern signal in a pattern corresponding to saidscanning pattern.
 5. A method of creating in a digital memory apositionally oriented digital representation of the outline and distinctlight intensity variations of a natural tobacco leaf having twogenerally parallel large area surfaces, said method comprising the stepsof:(a) supporting said leaf in a spread condition on a member; (b)illuminating said leaf to create an emitted light ray patterncorresponding to the shape and surface coloration of said leaf; (c)measuring the emitted light intensity at known locations on saidsupporting member, said locations combining to cover said leaf and partof said member; (d) creating a digital representation for each of saidlocations, said representation being:(i) a first digital signal when thelight intensity for said location is above a selected first level; (ii)a second digital signal when the light intensity for said location isbelow a selected second level; or, (iii) a third digital signal in theabsence of said first and second digital signals for said location; (e)creating a digital transition signal for each of said locations whereinsaid digital representation shifts from one of said digital signals toanother of said digital signals; and, (f) storing in said memory each ofsaid digital transition signals and information identifying the locationthereof.
 6. A method of creating in a digital memory a positionallyoriented digital representation of the outline and distinct lightintensity variations of a natural tobacco leaf having two generallyparallel large area surfaces, said method comprising the steps of:(a)supporting said leaf in a spread condition on a member; (b) illuminatingsaid leaf to create an emitted light ray pattern corresponding to theshape and surface coloration of said leaf; (c) measuring the emittedlight intensity at known locations on said member, said locationscombining to cover said leaf and part of said member; (d) creating adigital representation for each of said locations, said representationbeing:(i) a first digital signal when the light intensity for saidlocation is above a selected first level; (ii) a second digital signalwhen the light intensity for said location is below a selected secondlevel; or, (iii) a third digital signal in the absence of said first andsecond digital signals for said location; (e) creating a digitaltransition signal for each of said locations wherein said digitalrepresentation shifts from one of said digital signals to another ofsaid digital signals; (f) creating a digital address code for each ofsaid locations; and, (g) storing in said memory each of said digitaltransition signals and said digital address code identifying thelocation of said transition signal.
 7. A method of creating in a digitalmemory a positionally oriented digital representation of the outline anddistinct light intensity variations of a natural tobacco leaf having twogenerally parallel large area surfaces, said method comprising the stepsof:(a) supporting said leaf in a spread condition on an oriented lightray transmitting member; (b) passing light rays through said leaf andsaid member; (c) measuring the transmitted light intensity at selectedlocations on said member, said locations combining to generally coversaid leaf; (d) creating a digital representation for each of saidlocations, said representation being:(i) a first digital signal when thelight intensity for said location is above a selected first level; (ii)a second digital signal when the light intensity for said location isbelow a selected second level; or, (iii) a third digital signal in theabsence of said first and second digital signals for said location; (e)creating a digital transition signal for each of said locations whereinsaid digital representation shifts from one of said digital signals toanother of said digital signals; and, (f) storing in said memory each ofsaid digital transition signals and information identifying the locationthereof.
 8. A method of creating in a digital memory a positionallyoriented digital representation of the outline and distinct lightintensity variations of a natural tobacco leaf having two generallyparallel large area surfaces, said method comprising the steps of:(a)supporting said leaf in a spread condition on an oriented light raytransmitting member; (b) passing light rays through said leaf and saidmember; (c) measuring the transmitted light intensity at known locationson said member, said locations combining to generally cover said leaf;(d) creating a digital representation for each of said locations, saidrepresentation being:(i) a first digital signal when the light intensityfor said location is above a selected first level; (ii) a second digitalsignal when the light intensity for said location is below a selectedsecond level; or, (iii) a third digital signal in the absence of saidfirst and second digital signals for said location; (e) creating adigital transition signal for each of said locations wherein saiddigital representation shifts from one of said digital signals toanother of said digital signals; (f) creating a digital address code foreach of said locations; and, (g) storing in said memory each of saiddigital transition signals and said digital address code identifying thelocation of said transition signal.